Busway Systems
Class 5600
CONTENTS
Schneider Electric Brands
Description
Page
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Layout and Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation, Special Features, and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
225 A–600 A Catalog Numbering System/Physical Data . . . . . . . . . . . . . . . . . . . . . 33
800 A–5000 A Catalog Numbering System/Physical Data . . . . . . . . . . . . . . . . . . . . 42
Catalog Numbering System/Plug-In Units (“Bus Plugs”) . . . . . . . . . . . . . . . . . . . . . 59
Suggested Busway Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
100 A Plug-In Busway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
100 A Plug-In Busway Suggested Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
POWER-ZONE™ Metal-Enclosed Busway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
POWER-ZONE Metal-Enclosed Busway Suggested Specifications. . . . . . . . . . . . . 86
Busway Systems
Contents
PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sandwich Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Totally Enclosed Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compact Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Plating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dielectric Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VISI-TITE® One Bolt Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EZ JOINT PAK™ Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Labor Savings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Tie Channels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Internal Smoke/Gas Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Short Circuit Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Voltage Drop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Outdoor Busway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Universal Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Integral Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Plug-in Busway 225 A–600 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Plug-in Busway 800 A–5000 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Indoor Feeder Busway 800 A–5000 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Outdoor Feeder Busway 800A–5000 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
APPLICATION DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
The Four Types of Busway Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Service Entrance Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Plug-In Type Vertical Riser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Plug-In Type Horizontal Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Feeder Type Tie Run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Service Entrance Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Service Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Transformer Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bussed Transformer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Other Service Entrance Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Plug-in Busway Horizontal Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Plug-in Risers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Riser Installation and Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Special Manufacturer’s Recommendation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Plug-In Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Feeder Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Busway Through Walls and Floors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Contents
LAYOUT AND MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Layout And Measurement of Busway Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Known Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION, SPECIAL FEATURES, AND SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Painting Installed Busway Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hanger Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maintenance Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Special Busway Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Special Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Low Current Density Busway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Riser Plug-in Busway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Drip Resistant to IP-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Busway Measuring and Layout Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Emergency Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
“Missing Link” Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Busway “Quick Ship” Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
How To Properly Measure Your Missing Link(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Electrical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Voltage Drop Sample Calculations (60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Sample No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Sample No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Voltage Drop Data (60 Hz At Rated Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
I-LINE® Busway Catalog Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Straight Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Joint Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cable Tap Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Tees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Expansion Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Unfused Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Flanged End Cutout And Drilling Template. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Flanged End Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Flatwise Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Edgewise Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Sway Brace Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Vertical Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Vertical Spring Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
End Closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wall And Floor Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Required Wall Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Busway Catalog Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
800 A–5000 A CATALOG NUMBERING SYSTEM/PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . 42
Cross Sections—Plug-In and Indoor Feeder Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cross Sections—Fittings and All Outdoor Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Straight Lengths—Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Contents
Straight Lengths—Plug-in (Indoor Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Qwik Flange (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Qwik Flange (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Flanged End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Flanged End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Qwik Flange And Flanged End Termination Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Detail of Phase Bussing Connections in a Switchboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Offset Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Double Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cable Tap Box–End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cable Tap Box–Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cable Tap Box–Bolt On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Unfused Reducer (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Expansion Fitting (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Tees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Service Head Flatwise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Transformer Tap (One 3Ø Transformer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Service Head Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Straight Length With Flanged Collar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Roof Flange Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Transformer Tap (Three 1Ø Transformers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Adapter (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Phase Transition (Indoor Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Hanger–Horizontal Flatwise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Hanger–Horizontal Flatwise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Hanger – Horizontal Edgewise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Hanger–Vertical Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Hanger–Vertical Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Wall and Floor Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
End Closure (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CATALOG NUMBERING SYSTEM/PLUG-IN UNITS (“BUS PLUGS”) . . . . . . . . . . . . . . . . . . . . . . . . 59
Plug-In Catalog Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Type of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fusible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Plug-In Device Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Special Purpose Plug-In Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Horsepower Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Interrupting Capacity of Fusible Switch Plug-In Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Interrupting Capacity of Circuit Breaker Plug-In Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Required Clearances for Plug-In Unit Mounting
(Check These Dimensions Carefully Before Installing Busway Lengths) . . . . . . . . . . . . . . . . . . 62
Vertical Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Fusible Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Circuit Breaker Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Fusible Switch Plug-In Units—30 A–100 A (Type “PQ”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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Fusible Switch Plug-In Unit–200 A (Type “PQ”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fusible Switch Plug–In Unit 200 A (Type “PS”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fusible Switch Plug–In Unit 400 A (Type “PBQ”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fusible Switch Plug-In Unit— 600 A (Type “PBQ”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fusible Switch Plug-In Unit— 400 A (Type “PBQA”). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fusible Switch Bolt-On Units — 800 A–1600 A (Type “PTQ”). . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Circuit Breaker Plug-In Units—15 A–250 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
I-LIMITER® Current-Limiting Circuit Breaker Plug-In Units—15 A–250 A . . . . . . . . . . . . . . . . . 67
I-LIMITER® Current-Limiting Circuit Breaker Plug-In Units— 300 A–600 A. . . . . . . . . . . . . . . . 68
Circuit Breaker Plug-In Units—250 A–400 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Circuit Breaker Plug-In Units—300 A–600 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Circuit Breaker Bolt-On Units—500 A–1600 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Combination Fusible Switch and Starter—Lighting Contactor—Contactor . . . . . . . . . . . . . . . . 70
Ground Detector and Neutralizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Combination Circuit Breaker And Starter — Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SUGGESTED BUSWAY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.1 Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.2 Regulatory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.3 Delivery, Storage, and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.0 Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.1 Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.2 Manufactured Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.3 Basic Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.4 Support of Busway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.5 Voltage Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.6 Plug-In Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.7 Plug-In Unit Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
100 A PLUG-IN BUSWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
UL Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Ground Bus (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Bus Bar Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Short Circuit Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Voltage Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Straight Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Joint Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Busway Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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Cross Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Tees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Wall Flange End Closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
End Closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Outer Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Circuit Breaker Plug-In Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Cable Tap Boxes – Plug-In Cable Tap Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Floor Operated Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
100 A PLUG-IN BUSWAY SUGGESTED SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.1 Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.2 Regulatory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.0 Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.1 Manufactured Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.2 Basic Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 2.3 Bus Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.4 Support of Busway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.5 Plug-In Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
POWER-ZONE™ METAL-ENCLOSED BUSWAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Housing Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Housing Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Conductor Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
POWER-ZONE Bus Standard Construction: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Bus Bar Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Bus Bar Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Bus Bar Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Housing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Bus Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Layout and Pricing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Fitting Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Transformer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Generator Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Bushing Box (Weatherhead) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Wall Entrance Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Equipment Entrance Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Expansion Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Housing Bellows (Misalignment) Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Flanged Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Cable Tap Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Supporting Steel (Hangers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Hazardous or Seismic Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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General Pricing Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Weatherproof Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Typical Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
POWER-ZONE METAL-ENCLOSED BUSWAY SUGGESTED SPECIFICATIONS . . . . . . . . . . 86
1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.1 Section Includes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.2 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.0 Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.1 Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.1 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.3 Phase Bus Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.4 Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.5 Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Product Description
General
Totally Enclosed Housing
I-LINE® Busway manufactured by Square D offers a complete line
Ventilated busway depends on free
air movement through a perforated
housing to cool the bus bars.
Unless mounted in its preferred
position (maximum bus bar
cooling), ventilated busway must be
derated. Ventilated housing also
permits dirt accumulation and offers limited protection of bus
bars due to open ventilating slots in the housing.
of compatible, sandwich-type feeder and plug-in busway lengths
and fittings. It allows maximum flexibility, ease of installation, and
offers electrical efficiency in the distribution of low voltage power
for both commercial and industrial applications.
I-LINE busway has been used to supply power in thousands of
installations throughout the world for more than three decades.
Our broad range of I-LINE busway products include: I-LINE
Plug-In style from 225 A–600 A with aluminum or copper
conductors; I-LINE® II Plug-in and Feeder styles from 800 A to
4000 A with aluminum conductors, and to 5000 A with copper
conductors. I-LINE and I-LINE II busways are constructed in
three-pole and four-pole full neutral configurations for system
voltages to 600 Volts and are rated to allow 100% of the current
to flow continuously.
Busway installation is quick and easy. The compact, totally
enclosed design is lightweight and easy to handle. Labor
studies have shown that a 75% savings in installation time is
not uncommon when comparing I-LINE busway with cable and
conduit installations. This significant reduction in installation
time can result in total installed cost for busway being
significantly lower than other distribution methods.
In addition, a wide variety of busway components and plug-in
units are available from stock for fast delivery.
I-LINE busway has a modern
“totally enclosed” housing
design requiring no derating
regardless of mounting position.
Because the housing has no
ventilating holes, the entry of dirt
and possibility of accidental
contact with bus bars is greatly
reduced.
Compact Size
I-LINE II busway is compact. The small size means it may be
used in locations where feeder circuits would not otherwise be
possible. Efficient use of light-weight raw materials is an
additional factor in I-LINE busway’s compact design.
When you need busway, select the best—I-LINE busway. Our
design and construction has been time-tested in many years of
use throughout the world. No matter how you compare, I-LINE
busway is your solid first choice!
Sandwich Construction
I-LINE feeder and plug-in busway both utilize sandwich-type
construction to provide superior voltage drop characteristics,
even at low power factors.
Steel housing sides and aluminum tops and bottoms have
been carefully designed to reduce component weight and
minimize the hysteresis and eddy current losses that are
common in all steel housings.
Plug-in busway ratings that utilize two or three bus bars per
phase have a phase paralleling feature at the joint assembly of
each straight length. This helps equalize bus bar loading when
plugs are mounted on one side only.
The plug-in housing has notches along the top rail for easy
alignment and installation of plug-in units.
Within the same ampere rating, all I-LINE II busway lengths
and fittings are fully compatible between feeder and plug-In
styles using standard universal tie channels (housing “splice
plates”) supplied with each component.
Finish
I-LINE busway housing appearance has been further
enhanced by the addition of a multi-million dollar cationic
electro-deposition paint system to our production facility.
I-LINE busway users get a tough, durable uniform “E-Coat”
epoxy paint finish, making their busway installations functional
and attractive for years to come.
Insulation
All bus bars are insulated using Class B rated (130 °C (266 °F)
vendor certified) materials to prolong insulation life. I-LINE
busway insulation consists of two layers of heat-formed
polyester film surrounding each bus bar. On plug-in busway
lengths, all insulation is notched at the openings to allow plugin unit mounting.
9
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Product Description
I-LINE II busway uses the same two layers of polyester film to
insulate the bus bars in indoor busway while outdoor busway
utilizes powder-coated epoxy insulation for the bus bars. Both
types of insulation offer high quality dielectric strength and long
life expectancy.
Plating
Bus bars for I-LINE and I-LINE II busway are plated to ensure
low surface-to-surface contact resistance and to minimize
surface corrosion. Aluminum bus bars are electroplated with a
coat of tin after preparation with the ALSTAN 70 process.
Copper bus bars are plated with a layer of silver that is flashed
onto the surface of the bus bar.
EZ JOINT PAK™ Connector Assembly
I-LINE II busway offers an improved single bolt joint package which
can be removed and replaced with an isolation joint pak to
electrically isolate busway sections for load shifting and
maintenance. It can also be relocated to the opposite end of a
length to take care of last minute job changes. The EZ JOINT
PAK™ Connector Assembly is shipped pre-assembled with each
I-LINE II busway length or fitting, providing minimum job-site
installation labor. And the VISI-TITE bolt is a standard feature on all
assemblies.
Dielectric Testing
UL® and CSA require a one-time dielectric test for all new
busway designs prior to certification. This test, at two times
rated voltage plus 1000 Vac (2200 Vac), is intended to confirm
the integrity of the insulation system. I-LINE busway passes this
test.
Every length and fitting of our busway must also pass a
7500 Vdc “hi-pot” test before shipment from the factory. This
additional test helps ensure the highest quality busway possible
for our customers.
VISI-TITE® One Bolt Joint
I-LINE busway incorporates the “one bolt”
joint principle. This joint design uses a
high-strength (Grade 5)
VISI-TITE® bolt to provide a clamping force
of over 4000 pounds. The force is
distributed over the contact area by a pair
of large diameter, spring steel cupped
conical washers. On higher ampere ratings
(2000 A or above) two or three joint bolts
are used-one for each set of bus bars. Our
“one bolt” principle replaces older designs
which required up to 32 nuts, bolts, and
washers for each set of bus bars. The VISI­
TITE torque indicating joint bolt is standard
on all busway joints. Insulated and at
ground potential, the bolt and nut are both
captive to reduce installation time.
Fast, accurate torquing is a snap with VISI­
TITE double- headed bolts. There’s no need for a torque
wrench. Use any long handled wrench to tighten the outer bolt
head until it twists off and releases a red plastic warning disc.
Any disc remaining during inspection indicates an improperly
torqued joint. For maintenance of the joint or when busway is
relocated, the VISI-TITE bolt should be tightened to 70 lb-ft +/10 lb-ft (94.92 N•m +/- 13.56 N•m) with a torque wrench.
Labor Savings
I-LINE II busway installs quickly compared to other forms of low
voltage power distribution. While material costs may be slightly
higher, the labor required to install I-LINE II busway is often
much lower. This results in an overall reduction in total
installation cost.
Total Installation Cost
Labor
Labor
Material
Material
I-LINE
Busway
Other
Distribution
Methods
10
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Product Description
Tie Channels
Quality
I-LINE II busway uses one set of universal tie channels for all
ampere ratings of busway–both feeder and plug-in. This helps
speed up busway installation.
All I-LINE busway products are manufactured in a Square D
facility which has been registered by Underwriter’s
Laboratories, Inc. to ISO 9001:2000.
Internal Smoke/Gas Barriers
Continuous air spaces inside I-LINE II busway housing are
closed off with special barriers to help prevent the spread of
smoke and gases in the event of a fire in the area of the
busway installation. This standard internal barrier allows
busway to extend through walls or floors without creating open
space for a “chimney effect” fire path.
I-LINE busway from 225 A–600 A requires installation of a
special internal barrier for wall or floor penetrations.
Short Circuit Strength
Integral Ground Bus
I-LINE II busway (800 A–5000 A) is built with an innovative
Integral Ground Bus (IGB) system, proven by many years of
use on original I-LINE busway installations.
In simple terms, IGB utilizes two 1/16-inch thick ground bus bars to
form the housing top and bottom. This provides an integral 50%
continuous current capacity ground path. Equally important, the
two ground bus bars completely encircle the phase conductors
and provide a very effective high level ground path for ground
faults. Copper integral ground is available as an option.
I-LINE busway housing construction gives high short circuit
ratings. On some feeder busway, additional short circuit strength
is gained by wrapping the bus bar sandwich with epoxy saturated
fiberglass tape. This results in ratings of up to 200,000 RMS
symmetrical for 4000 A and 5000 A feeder busway.
We believe a properly designed ground should be included on
all distribution systems. I-LINE II busway includes IGB as a
standard feature on every rating from 800 A to 5000 A.
On plug-in busway, molded plug-in opening insulators (or
optional high strength insulators) provide additional short
circuit strength. Full short circuit bracing extends across the
plug-in opening to protect the plug-in connections.
We offer many products and services to fulfill the need for
complete and reliable grounding throughout your electrical
system. Consult your local sales office for assistance in this
very important aspect of proper electrical design.
Our busway has been tested under actual short circuit
conditions at the Square D High Power Laboratory in Cedar
Rapids. These tests confirm I-LINE busway can withstand
extremely high short circuit levels. Some ratings actually stand
up to tests at 200,000 RMS symmetrical amperes!
Voltage Drop
Because of its extremely low reactance, I-LINE busway voltage
drop is low. This efficient design allows power to be delivered
in an installation with the highest efficiency possible. This
makes I-LINE busway ideal for efficient power distribution in
commercial or industrial facilities.
(Integral ground bus is available as an option on 225 A–600 A
busways.)
Steel side channel
(2) for mechanical
strength
Ground bus/
Housing top (1/16-inch
Aluminum bus bar)
Outdoor Busway
Outdoor feeder busway is furnished with a housing
construction employing a special gasketed design to prevent
the entry of rain. Unique engineering and design features allow
field installation in any mounting position while still maintaining
outdoor integrity. This product symmetry provides for proper
installation in all instances. The VISI-TITE bolt is also standard
on outdoor busway.
Bus bars
Ground bus/
Housing bottom
(1/16-inch Aluminum
bus bar)
Top
I-LINE II
Busway
Cross Section
Including
Standard Integral
Ground Bus (IGB)
Universal Fittings
I-LINE II busway fittings are designed for use with feeder and
plug-in busway straight lengths as well as for continuations of
service entrance busway runs. The compact universal fittings
allow maximum layout flexibility without the need for special
built-to-order combination fittings.
Continuous bonding between
top and bottom ground bus
11
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© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Construction
Plug-in Busway 225 A–600 A
1. Integral Ground Bus (IGB)—Is furnished as an optional
feature for I-LINE busway and rated at 50% capacity of the
nameplate Amperage rating of the busway. The conductor is
aluminum and is the top part of the housing itself.
2. VISI-TITE Bolt—Is a double-headed bolt furnished for all joint
connectors to ensure proper torque for each connection. A
cupped conical washer is also included to ensure equal distri­
bution of pressure across the full joint surface area.
3. Plug-in Openings—Is furnished standard with plug-in
openings on 2 ft (61 cm) centers on both sides of I-LINE
busway. The openings include a hinged door that covers the
opening when it is not in use. A 600 A maximum capability is
at each plug-in opening. Hangers for the busway fit without
blocking access to the plug-in opening.
4. The Enclosure—Is a three-piece formed housing with plug-in
openings supported by molded rigid insulators.
NOTE: Insulation for I-LINE busway is two full-length layers of
Class B rated (130 °C (266 °F) vendor certified) polyester film.
12
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Construction
Plug-in Busway 800 A–5000 A
1. Molded plug-in opening insulator—Adds insulation and
support at plug-in contact area.
NOTE: Internal barriers are standard on both feeder and plugin busway. All interior spaces are barriered to stop hot gases.
2. EZ JOINT PAK connector assembly—Includes like-phase
connector on higher ampere ratings with more than one
conductor per phase (plug-in bus only).
NOTE: Hangers fit both feeder and plug-in busway without
blocking access to openings.
3. Ground jaw for plug-in unit—Has a “blow-on” design similar to
phase jaw connection.
4. Fittings—Includes elbows, tees, and flanged ends that are
easily removed and refitted with the use of our EZ JOINT PAK
assembly without disturbing adjacent lengths.
NOTE: I-LINE plug-in units (15 A–1600 A) fit both original and
I-LINE II busway.
NOTE: I-LINE II plug-in busway with sandwich construction also
includes features depicted for feeder style on page 14.
13
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Construction
Indoor Feeder Busway 800 A–5000 A
1. Steel housing channels—Provides mechanical strength.
2. Molded extra-strength glass fiber interphase barriers.
3. EZ JOINT PAK connector assembly—Removable for
isolation or maintenance. Includes VISI-TITE bolt.
4. Steel/aluminum housing—Reduces hysteresis and eddy
current losses on feeder and plug-in busway.
a Electrodeposition paint process—Provides lasting uniform
appearance.
a Housing sizes—Are the same for I-LINE II feeder and
plug-in busway. Same accessories fit both.
a Insulation— Is Class B rated (130 °C (266 °F) vendor
certified) insulation.
a Optional Fiberglass tape and epoxy resin—Improves short
circuit strength (Type AFH2/CFH2).
5. Plated aluminum or copper bus bars.
6. Surge clamps for added short circuit strength.
7. Integral Ground Bus (IGB) —Two, 1/16-inch thick aluminum
bus bar. Also serves as top and bottom housing.
14
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Construction
Outdoor Feeder Busway 800A–5000 A
1. Joint Covers— Two-piece joint cover with quick-fasten nut for
speedy installation of the busway.
2. EZ JOINT PAK—The same joint pack used on our indoor
I-LINE II busway is continued in our Outdoor Feeder design.
NOTE: Supports are required on 5 ft (152 cm) centers for
vertical or horizontal mounting. Normally, the support for
outdoor busway is in the form of a T-stand type device, which
is customer supplied. However, hangers are available from
Square D when drop rods can be utilized.
3. Flanged Collar—Simple installation of the joint covers is
assisted by a smooth flange surface with the joint sealant strip
factory installed. Removal of the sealant’s protective paper
covering and installation of the joint covers with the quick
fasten nut, seal the joint from contamination by water.
4. Removable Drain Plug—The outdoor feeder design includes
removable drain plugs to allow condensation to escape from
the joints. These drain plugs should be removed only as
described in the installation instructions for outdoor feeder
busway.
5. Completed Joint—The assembled joint with all installation
activities complete.
15
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© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Construction
Listed below are the four basic types of busway applications:
• Service Entrance Run
• Plug-In Type Horizontal Run
• Plug-In Type Vertical Run
• Feeder Type Tie Run
In addition to the information that is electronically entered into the Product Selectors, the information needed by Oxford to engineer
a busway run is listed below. A busway run may consist of more than one type of application.
Type of
Application
1
2
3
4
S
E
R
V
I
C
E
H
O
R
I
Z
O
N
T
A
L
V
E
R
T
I
C
A
L
T
I
E
✓
✓
✓
✓
A. Layout sketch of busway run
✓
✓
✓
✓
B. All necessary dimensions
✓
✓
✓
✓
C. Positions of equipment (fronts or rears)
✓
✓
✓
✓
D. Phasing of existing equipment or equipment by others
✓
✓
✓
E. Location of walls (if applicable)
✓
Order Number: _______________________________________
Completed by: ____________________________________
Field Office: _________________________________________
Date: _____________________________
(✓) = Required Information
✓
✓
Busway Order Entry Checklist
F. Location of floors (floor to floor dimensions)
✓
✓
G. Wall thickness (if applicable)
H. Floor thickness
✓
✓
I. Location of roof (if applicable)
✓
✓
J. Roof thickness (if applicable)
K. Special requirements noted on busway sketch (e.g., special lugs, critical dimensions)
✓
✓
✓
✓
✓
✓
✓
✓
✓
N. Indicate location of plug-In busway on sketch
✓
O. Indicate the side of the busway that the plug-in units are to be mounted
✓
P. Indicate if there are any curbs where busway passes through floors
✓
Q. Curb thickness (in addition to the floor thickness)
✓
✓
L. Indicate appropriate service device (e.g., tap box, service head, x’fmer. tap, bussed)
✓
M. Equipment details if connecting busway to other than Square D equipment
R. Indicate type of vertical hangers (spring or fixed)
✓
✓
✓
✓
S. If connecting to existing I-LINE® I, indicate bolt or slot connection
✓
✓
✓
✓
T. If connecting to other than Square D busway, send a piece of that busway to Oxford
✓
✓
✓
✓
U. Switchboard identification markings noted on busway sketch
Notes: (1) For detailed illustrations refer to pages 17–27.
(2) Lack of all required information causes delays in order processing and can affect the delivery schedule.
(3) If additional assistance is required, contact Square D at 1-888-SQUARE D (1-888-778-2733).
16
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Application Data
The Four Types of Busway Runs
There are four major types of busway applications. Figures 1– 4 illustrate the basic systems.
Service Entrance Run
Plug-In Type Horizontal Run
Figure 1 is a typical service entrance run from a utility
transformer to a switchboard. Cables connect directly to the
busway. (Generally a combination outdoor-indoor application.)
Figure 2 is a simple plug-in run fed by a switchboard through a tee. (Always an indoor application.)
To
p
To
p
Re
a
of r
SW
BD
Fr
Wall
R
FM
X
on
of t
SW
BD
Figure 2
Figure 1
Plug-In Type Vertical Riser
Feeder Type Tie Run
Figure 3 is a simple plug-in riser fed by a switchboard. (Always
an indoor application.)
Figure 4 is a typical feeder run between two switchboards.
(Generally an indoor application.)
T
O
P
Plug-in Units
Mount This Side
T
O
P
T
O
P
3rd Floor
2nd Floor
1st Floor
t
on
Fr f
o D
B
SW
ar
Ref
o D
B
SW
t
on
Fr f
o D
B
SW
Figure 4
Figure 3
17
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Application Data
Service Entrance Runs
Service Heads
I-LINE II busway can be used as a service entrance conductor
to bring power from a utility transformer into a distribution
switchboard. Cable or solid bussing is used to connect to
the transformer.
If the busway specifications or local utility require that for the
service entrance cable-to-busway termination be enclosed in a
weatherproof box, then a service head should be ordered.
When the transformer is connected to the busway using
cables, the governing electrical code may specify height
clearance requirements for the cables.
Vertical service
head
28.00
711
29.00
737
X
X
X
X
X
Refer to code for minimum
height requirements.
Indoor
Outdoor
X
Ground level
All "X" dimensions must be known.
Switchboard phasing must also be known.
X
Dual Dimensions: INCHES
Millimeters
Figure 6: Typical vertical service head application
If the flatwise busway elevation is too low to allow a cable
connection that would comply with the electrical code, another
solution is the Vertical Service Head (29SV). The vertical
service head can be attached to busway that exits the rear of
the switchboard (see Figure 6) and is turned upward, or can be
attached to busway that exits the top of a switchboard and
penetrates the roof utilizing a drip flange and roof collar (see
Figure 7 on page 19).
X
For X dimensions
refer to (NEC® Article 230-24).
Figure 5: Typical connection of transformer to busway using cables
Figure 5 illustrates the dimensions to be considered when
planning this type of run.
18
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Application Data
Indoor
15.00
381
28.00
711
Note: Integral weather seal
supplied where busway
passes through roof.
All "X" dimensions must
be known.
X
Outdoor
71.00
1803
X
Dual Dimensions: INCHES
4.00
Millimeters
Outdoor
X
X
102
minimum
X
X
Cables
Indoor
See Detail A
X
Switchboard
Wall
All "X" dimensions must be known.
Dual Dimensions: INCHES
Transformer
Switchboard
Millimeters
Figure 8: Transformer tap for one three-phase transformer
Drip flange
X
X
6.00
152
X
8.00
203
X
120.00
6.00
3048
152
Roof
collar
Detail A
XFMR
Roof
XFMR
XFMR
Switchboard
Figure 7: Vertical service head penetrating a roof
If a vertical service head extends through a roof, the roof must
be sealed around the busway. To do this, a fixed collar must be
factory assembled onto the section of busway that penetrates
the roof. The contractor can then flash from the collar to the
roof. A roof flange kit can be ordered from the factory to make
the flashing job easier. The kit consists of a drip flange and a
roof collar. When installed, the roof collar must be sealed to
ensure that no moisture gets indoors. The roof flange kit will
accommodate a roof slope up to one inch per foot. See
Detail A in Figure 7.
Wall
All "X" dimensions must be known.
Dual Dimensions: INCHES
Millimeters
Figure 9: Transformer tap for three single-phase transformer
Transformer Taps
A transformer tap performs the same function as a service
head, except that the lugs and bussing to which the service
entrance cables are connected are not enclosed in a weather­
proof enclosure.
A Flatwise Service Head (71SB) with the box removed is
therefore a Transformer Tap (71SF). A (71SF) is a transformer
tap for one three-phase transformer. Figure 8 illustrates a
typical 71SF service entrance run.
If three single-phase transformers are supplied by the utility to
deliver power to the customer, a separate transformer tap has
been designed for this application. This transformer tap is
known as a “TTF” and is shown in Figure 9.
19
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Application Data
Bussed Transformer Connections
Phasing
If required, the factory can provide a bussed transformer
connection. This type of connection will include flexible
connectors from the low voltage spades of the transformer to
the busway connectors. These flexible connectors are used to
allow for busway expansion and contraction on the low voltage
spades. Positioning of these flexible connectors is critical for
proper alignment between the busway and transformer.
When a bussed transformer connection is to be used, it is
essential that the phasing of the transformer and of the
switchboard it supplies be properly coordinated. It is sometimes
best to let the manufacturer coordinate the phasing. Simply
supply the name of the transformer manufacturer and phasing
details of the low voltage side.
Other Service Entrance Connections
Bussed transformer connections are usually made to two types
of transformers. One type has a low voltage throat as shown in
Figure 10, and the other is a padmount type with a low voltage
compartment shown in Figure 11 on page 21.
Occasionally, the customer or local utility will require a service
entrance connection that differs from our standards. In this
case, be sure to inform the factory of any special dimensions,
such as required height of service head from ground or floor,
spacing between phase bars, number and type of lugs,
distance from lugs to wall, phasing, etc.
Information Needed for Transformer Connection
Front
LV spades
Outdoor
X
X
X
Indoor
X
LV throat
X
X X
Top View of Transformer
CL of Bushing
X
Top of
transformer
X
X
X
X
X
X
X
X
X
Front of switchboard
CL Bushing
X
Indicate number of holes,
diameter of holes, and
spacing between holes.
Edge of
throat collar
Side View of
Transformer
X
Note: Often the floor level and
outdoor ground level will be at
different heights.
X
X
All “X” dimensions must
be known.
X
X
Transformer
tank wall
X
X
X
X
"X" Number and
diameter of holes
"X" Thickness
LV Spade Detail
Figure 10: Measurements needed for bussed transformer connection (throat type)
20
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Application Data
X
X
X
X
LV spades
X
Outdoor
X
X
Front View of Transformer
Indoor
X
LV spades
Front of
transformer
X
X
X
CL
CL
X
X
X
X
X
Note: Often the floor level
and outdoor ground level
will be at different heights.
Side View of Transformer
X
All "X" dimensions must be known.
Note: In the low voltage compartment, the busway
should be oriented so that the phase bars
are parallel with the transformer LV spade.
X
Switchboard
X
X
X
X
X
Transformer
tank wall
X
X
"X" Number and
diameter of hole
"X" Thickness
of spade
LV Spade Detail
Figure 11: Measurements needed for bussed transformer connection (pad mount type)
21
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Application Data
busway phasing must be followed, it is the busway that will
determine the phasing of the switchboard.
Plug-in Busway Horizontal Run
Plug-in busway is used as a means of bringing power from a
distribution switchboard to multiple loads throughout a building
or manufacturing facility.
NOTE: Plug-in busway has the integral ground bus plug-in jaw
on the top side only.
Phasing
Identification
A typical I-LINE II plug-in run is shown in Figure 12. The phasing
shown on the plug-in busway is “GABCN” top to bottom, with the
top located as shown for a horizontal run. This phasing
arrangement must always be followed so that proper phasing of
the plug-in units will be ensured (see Detail A). Because this
When submitting busway run sketches for review, ensure that
the plug-in busway sections are marked (P).
Notches in top rail position unit.
Hooks support weight of device
during installation.
Top
G
A
B
C
N
Detail A
“Hook-Swing” Mounting
CL
P
X
X
To
p
To
P
p
X
P
X
X
p
To
End
closure
G
A
B
C
N
To
p
Unfused
reducer
P
X
X
Plug-in
unit
p
To
G
A
B
C
N
X
P
NC
BA
G
X
End
closure
X
All “X” dimensions must be known.
P Indicates plug-in devices.
Rear of switchboard
Figure 12: Measurements needed for a typical plug-in type run
22
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Application Data
Plug-in Risers
I-LINE II plug-in busway can be utilized for the entire vertical
riser. There is no need to use feeder busway to penetrate the
floors. This feature enables the use of more plug-in openings
per floor of the riser. (Plug-in risers under 800 A require internal
barriers where the busway passes through a floor.)
NCBAG
X
3rd Floor
X
Plug-in
units mount
this side
Dimensions
The riser in Figure 13 has been fully dimensioned. Note that
feeder style busway has been used out of the switchboard and
the two 120-inch (3048 mm) sections of plug-in style busway
on the second and third floor do not have a joint located in or
near the floor. Refer to page 25 for a discussion and detail of
joint accessibility requirements.
Figure 14 shows typical dimensions that should be known to
ensure an accurate installation: floor-to-floor height, floor
thickness, exact layout of multiple run riser, closet dimensions,
the type and quantity of plug-in tap units per floor, which side of
the busway the units should mount on, and (if necessary) the
desired height of the units from the floor.
X
2nd Floor
X
X
X
X
X
NC
BA
G
1st Floor
Front of
switchboard
All “X” dimensions
must be known.
1.00
End closure
End closure
X
25
105.00
Figure 14: Typical information needed for riser
2667
3rd Floor
NCBAG T
o
p
120.00
Riser Installation and Phasing
3050
Plug-in
busway
15.00
381
Circuit breaker type and the 30 A, 60 A, and 100 A fusible type
plug-in units can be mounted on either side of the busway in
riser installations.
150.00
3810
120.00
3048
When fusible type plug-in units are being supplied, the location
of the plug-in unit determines the phasing of the busway. NEC
Article 380-6 and CEC Article 14.502 state: “Single throw knife
switches shall be mounted so that gravity will not tend to close
them”. It is essential that the busway be oriented with the
correct side available for the insertion of the units.
T
o
p
2nd Floor
15.00
381
27.00
686
Feeder
busway
12.00
305
120.00
3048
192.00
4877
83.00
To determine the correct busway orientation (based on where
the plug-in units mount for your installation), please contact
your local representative for assistance and coordination.
2108
1st Floor
NC
BA
G
Front of
switchboard
.50
Dual Dimensions: INCHES
13
Millimeters
Figure 13: Typical layout 800 A riser
23
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Application Data
The cost of removing and replacing a contaminated busway
length far exceeds the cost for including a waterproof curb
when the floors are poured.
NCBAG
Once busway is installed through a floor opening, the
remaining unused area should be filled to prevent smoke from
passing floor-to-floor (chimney effect) in case of fire in the
building. Some recommended materials available are fire rated
foam and caulk. Grouting is also acceptable, but must be
applied in a very dry form to prevent water and contaminants
from entering the busway once the grouting cures and the
water leeches out. Check with your local inspector to determine
the appropriate materials to be used in filling the void around
the busway.
Top
ON
OFF
Plug-In Units
Figure 15: Correct orientation of riser busway
Figure 15 shows the correct mounting and phasing of the riser
busway and plug-in unit. It is IMPERATIVE that the face
labelled “TOP” be installed as shown on the installation
drawings provided with your project.
Special Manufacturer’s Recommendation
NEC requires a waterproof curb to be installed at each floor
opening where busway passes through (see Figure 16). An
unprotected floor opening can act as a funnel for plumbing
leaks, sprinkler system leaks, fluid spills, and other types of
contamination.
When entering an order, the factory must know not only which
side of the busway the plugs will mount on, but also the type
and quantity of plugs to be used on each floor. Also, notify the
factory if the plugs need to be mounted at a certain height from
the floor.
Hangers
Spring hangers are recommended for riser applications. When
properly installed and maintained, spring hangers compensate
for expansion and contraction of the busway, as well as
shrinkage of the building. In riser applications, support for
busway must be provided at intervals not exceeding 16 ft
(488 cm).
Busway
Curb
Floor
4.00
102
Dual Dimensions: INCHES
Millimeters
Figure 16: Waterproof curb recommended at floor opening
24
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Application Data
Feeder Runs
Wall
Feeder type runs are normally used for distributing power to
loads that are concentrated in one area. Typical connections
are switchboard-to-switchboard tie runs (see Figure 17), or a
switchboard feeding a remote motor control center (MCC).
Edge of
tie channel
X
X
X
8.00
203
X
B
Tie channel
N
ABC
Wall
X
CL
Joint
G
Front of
Switchboard
“B”
Dimension B must be
greater than 8 inches (203 mm).
Dual Dimensions: INCHES
Millimeters
Figure 18: Joint accessibility requirements
G
Front of
Switchboard
“A”
BA
NC
Busway Through Walls and Floors
When 800 A–5000 A busway extends through a wall or floor,
feeder or plug-in busway can be used. For runs under 800 A,
plug-in busway will be used throughout. In all cases, wall or
floor location must be specified.
X
X
Figure 17: Measurements needed for feeder type run
According to CEC Article (12.2006) and NEC Article (364-4),
busway must be installed so that supports and joints are
accessible for maintenance purposes after installation. This
implies that no part of the tie channel can be inside the wall.
Therefore, the distance from the center line of the joint to the
wall must be greater than the distance from the center to the
edge of the tie channel (see Figure 18). If the dimensions of the
tie channel cannot easily be determined, it is best to keep the
joint at least 12 inches (305 mm) from wall. This will ensure
proper joint clearance for any type of busway passing through
a wall or floor.
25
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Layout and Measurement
Layout And Measurement of Busway Installations
Laying out and measuring a busway job does not require
specialized tools or skills. The following list of tools will
generally be sufficient:
2. Review the area where the busway could be installed (if not
already specified).
Note special conditions such as building expansion joints, steel changes, HVAC equipment, and plumbing lines.
3. Measure all dimensions from fixed points.
• 100 ft (3048 cm) tape measure
• Plumb bob/chalk line
• 25 ft x 1 in. (762 cm x 25 mm) tape measure
• Felt tip marker or crayon
• 6 ft (183 cm) wood rule
Let’s assume you want to feed a new motor control center
(MCC) with busway from a new distribution switchboard. Using
illustrations, we’ll go step by step through the layout process to
determine the busway orientation and dimensions. When
completed, we will have a single line isometric drawing
showing the proposed busway layout.
Known Information
From the bid documents, specifications, and/or factory
drawings, the following information is known:
• Busway is to be 1600 A, 3Ø4W 50% GND aluminum feeder
busway. (Width is determined to be 8.84 in. (225 mm).
• Switchboard is 7 ft x 7 1/2 in. (213 cm x 191 mm) high, 3 ft
(91 cm) wide, and 2 ft (61 cm) deep. Busway connection to
be in top center.
• Motor control center is 7 ft x 7 1/2 in. (213 cm x 191 mm)
high with a 1 ft (30 cm) additional height pull box for busway
connection; 20 in. (508 mm) wide; 20 in. (508 mm) deep.
Busway connection is in top center.
Measure dimensions such as columns, walls, or other
building structures. Try to leave at least 4 in. (102 mm)
between the busway and any obstructions. Figure 20 on
page 27 shows the switchboard and MCC locations, the
obstructions, and the dimensions to fixed points.
4. Start dimensional layout from the fixed end.
Sketch the proposed busway routing, noting elevations and
obstructions (see Figure 21 on page 27).
5. Route the busway above the bottom chord of the building
steel, unless specified.
For industrial applications, this protects the busway from
damage by forklifts, cranes, etc. The busway must be
supported by drop rods or from below. Do not route busway
where it cannot be adequately supported.
6. When selecting the elevation for plug-in busway, remember
that overcurrent devices (plug-in units) may require
different mounting clearances.
Referring to the sample busway layout, (see Figure 21),
enough information is known to tabulate the amount of
busway footage needed and the required fittings (e.g.,
flanged ends, elbows). A copy of the figure could help your
local sales representative with pricing your job, and also
could be forwarded to the factory to aid in preparation of
approval or record drawings.
• Bottom of busway (B.O.B.) to be installed 16 ft (488 cm) above finished floor (A.F.F.) unless obstructed.
1. Determine the physical size of the busway housing.
This information lets you know how far to stay away from
obstructions. In our example Figure 19, the busway is
8.84 in. (225 mm) wide and 5.88 in. (149 mm) high
(9 in. x 6 in. (229 mm x 152 mm) nominal).
Top
G
A
B
C
N
G
5.88
149
1600 A Al
8.84
225
Dual Dimensions: INCHES
Millimeters
Figure 19
26
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Layout and Measurement
360.00
9144
6
73.00
1854
G
A
B
C
N
A
CL
10.00
45.00
254
5
CL
1143
North
36.00
914
Front
of
switchboard
4.00
102
(Typical)
Dual Dimensions: INCHES
240.00
Millimeters
6096
(Typical)
Columns
12 in. x 12 in. (305 mm x 305 mm)
(Typical)
B
12.00
305
24.00
610
50.00
3 in. (76 mm) Steam line
Bottom of Pipe (B.O.P.)
16 ft (488 cm) Above Finished Floor (A.F.F.)
1270
6 in. (152 mm) Condensate line
B.O.P. 16 ft (488 cm) A.F.F.
4.00
102
20.00
508
Front of
MCC
NCBAG
20.00
508
20.00
508
CL
30.00
762
C
Figure 20: Plan view switchboard, MCC, and obstructions
360.00
9144
6
73.00
1854
A
CL
10.00
45.00
254
1143
Rise up
CL
8 ft 7 in. (144 cm 178 mm) (B.O.B. 4877 A.F.F.)
(E 4953 A.F.F.)
G
A
B
C
N
Front
of
switchboard
5
North
4.00
102
(Typical)
Dual Dimensions: INCHES
240.00
Millimeters
6096
Offset up
B
24.00
12.00
305
Columns
12 in. x 12 in. (305 mm x 305 mm)
(Typical)
12.00
305
610
50.00
1270
3 in. (76 mm) Steam line
Bottom of Pipe (B.O.P.)
16 ft (488 cm) Above Finished Floor (A.F.F.)
6 in. (152 mm) Condensate line
B.O.P. 16 ft (488 cm) A.F.F.
4.00
102
B.O.B. 17 ft (518 cm) A.F.F.
18.00
457
Offset down
20.00
12.00
508
305
Bottom of Busway (B.O.B.)
16 ft (488 cm) A.F.F.
Front of
MCC
NCBAG
20.00
508
20.00
508
Drop down
C
91.00
CL
30.00
762
2311
Figure 21: Proposed busway layout
27
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Installation, Special Features, and Services
Installation Recommendations
Hanger Spacing
To make the busway installation proceed as quickly and
efficiently as possible, a few preliminary steps should be taken.
Maximum support intervals include:
1. Familiarize yourself with the busway routing. If record
drawings were supplied by the factory, have a copy
accessible to the installers.
2. Inspect busway for damage when received. Store busway
in a clean, dry location.
3. Have the following recommended tools available for the
busway installation:
• 1/2-in. (13 mm) nut driver or socket and rachet
• Vertical mounting
— indoor–16 ft (488 cm)
— outdoor–5 ft (152 cm)
• Horizontal mounting
– indoor–10 ft (305 cm)
– outdoor–5 ft (152 cm)
Maintenance Recommendations
• Straight blade screwdriver
DANGER
• torque wrench or breaker bar with 5/8-inch (16 mm) head
• 3/4-in. (19 mm) socket for torque wrench or breaker bar
HAZARD OF ELECTRIC SHOCK, BURN OR EXPLOSION
• busway assembly tool (AT-2) for 800 A–5000 A (provided by
Square D)
• Electrical equipment should be serviced only by qualified
electrical maintenance personnel, and this instruction
bulletin should not be viewed as sufficient instruction for
those who are not otherwise qualified to operate, service,
or maintain the equipment discussed. Although
reasonable care has been taken to provide accurate and
authoritative information in this bulletin, no responsibility
is assumed by Square D for any consequences arising
out of the use of this material.
• A level
• Tape measure or 6 ft (488 cm) wood rule
• Busway insulation tester (“megger,” 1000 V recommended)
4. Carefully read the installation instructions for all devices
and NEMA Publication BU1.1-2000 provided with the
busway before installing any of the equipment. This will
help ensure proper installation and operation procedures
are followed for the busway system being installed. Note
the instructions call for the busway to be “meggered” before
and after installation.
5. Install busway hangers and supports. The most common
method of supporting the busway hangers is threaded drop
rods (or all thread) which the installer must supply.
6. Anticipate the weight of the objects being installed so the
necessary lifting devices and manpower are available.
• The successful operation of busway depends upon proper
handling, storage, installation, operation, and
maintenance. Neglecting fundamental installation and
maintenance requirements may lead to personal injury as
well as damage to electrical equipment or other property.
• Follow safety related work practices, as described in
NFPA 70E, part II, at all times.
8. Once the installation of the busway is complete, the NEMA
Publication BU1.1-2000 should be delivered to the facility
owner for his or her use in operating and maintaining the
busway system.
• Hazardous voltages in electrical equipment can cause
severe personal injury or death. Energizing busway for
the first time after initial installation or maintenance is
potentially dangerous. Unless otherwise specified,
inspect and perform preventive maintenance only on
busway and equipment to which power has been turned
off, disconnected, and electrically isolated so that no
accidental contact can be made with energized parts.
Painting Installed Busway Systems
Failure to follow these instructions will result in
death, severe personal injury, or equipment damage.
7. If any problems are encountered or questions arise, contact
your local representative.
A busway system, which includes plug-in units, may be painted
after installation. All precautions, however, must be taken to
prevent the paint from coming in contact with conductors and
insulation, and all nameplates and labels (safety labels, serial
number labels, UL Labels, etc.) remain visible and legible.
NEMA Publication BU1.1-2000 is provided with each busway
project as a guide for proper installation, operation and
maintenance of busway products. This publication addresses
such areas as inspection of all electrical joints and terminals for
tightness, prevention of entry of water and contaminants into
the busway, instructions for what to do if water and
contaminants do enter the busway, and other maintenance
topics. This publication is also available upon request by
contacting your local representative.
28
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Installation, Special Features, and Services
Other publications we recommend to help ensure the highest
quality of product performance are as follows:
NFPA 70–National Electrical Code (U.S.)
NFPA 70B–Maintenance of Electrical Equipment
NEMA BU1–Busway Standard published by the
National Electrical Manufacturers Association
CSA C22.1–Canadian Electrical Code, Part 1
Special Busway Construction
This section outlines requirements for busways with features
other than our standard.
Riser Plug-in Busway
We also offer an I-LINE II plug-in busway specifically designed
for installation in riser closets of high-rise buildings. This plugin busway has a plug-in door on the front side that faces out into
the room. The back of the busway, facing the wall is blanked off
with a feeder bus side rail.
This design provides a plug-in busway ideally suited for riser
cabinets and gives the customer only the necessary plug-in
openings. The catalog number for this device is the same as
our plug-in busway, except an R is substituted for the P.
(Example: if the standard plug-in busway prefix is AP2512G,
the riser busway prefix is AR2512G).
Drip Resistant to IP-54
Special Paint
I-LINE busway can be provided in colors other than ANSI 49
gray for a price add-on. The special color requested should be
specified by an ANSI color code at the time of order entry. With
typically lengthened lead times for special color parts, it is
imperative to provide this information as early as possible in the
order process so delivery commitments can be met.
Low Current Density Busway
Some customers require a lower current density busway than
our standard for rigorous duty in their installation. We have
developed a range of busway for the most commonly
requested current density of 1000 A per square inch for copper
busway. If you require this current density for your installation,
specify it, and we can meet your need. If you have requests for
another specific current density, contact your local
representative.
Some busway is located in indoor locations that are subject to
occasional water, such as roof leaks or sprinklers. While this
application does not require the full protection of outdoor
busway, additional protection is needed for the indoor busway.
This is where the Drip Resistant feature could be used. This
added feature to the busway is tested to the International
IEC-529 standard and is rated as IP-54. This rating specifies
protection from dust (“limited ingress permitted with no harmful
deposits”) and water (“splashed from all directions with limited
ingress permitted”).
This product is available as an option with indoor plug-in and
feeder busway. It is identified by the addition of “M54” at the
end of the standard catalog number.
29
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Installation, Special Features, and Services
Services
Busway “Quick Ship” Service
We pride ourselves in providing excellent service to our
customers the world over. We offer a wide range of services to
make the use of I-LINE busway as simple and easy as possible.
A summary of these services follows:
An extensive selection of busway is available for direct
shipment from the Oxford Distribution Center. This service will
allow you to order your busway today and have the order
shipped within two days. There is no need to wait for standard
busway devices. The following categories of busway devices
are included in the quick ship program.
Busway Measuring and Layout Service
We can provide full site measuring and coordination of a
busway installation. This service is ideal for large complicated
projects requiring close coordination with other services. This
service must be requested at the time of specification and order
entry. Refer requests for this service to your local
representative.
• 800 A–2000 A copper I-LINE II indoor feeder and
plug-in busway
• 800 A–3000 A aluminum I-LINE II indoor feeder and
plug-in busway
• 225 A–600 A copper and aluminum I-LINE plug-in busway.
All of the above in both:
— three-phase, three-wire
Emergency Service
Trained and qualified busway personnel are on call 24 hours
daily to assist in your emergency busway needs. Call
1-888-SQUARE D (1-888-778-2733) any time.
“Missing Link” Program
The “Missing Link” program is designed specifically to help a
customer correct last minute changes to a project using
busway. Those changes could include an unplanned
obstruction requiring the busway to be rerouted, incorrect
measurement of the busway run, or the need to order additional
pieces to supplement busway previously ordered. The program
applies to the United States, Canada, and Mexico, and
guarantees shipment of factory-built busway in five to seven
working days or we pay for the premium freight.
The program applies to I-LINE II (800 A–5000 A) indoor and
outdoor feeder busway straight lengths and elbows (90°, offset,
and double). Plug-in busway is not included in the program.
Straight lengths are available in one-inch increments from
16–120 in. (406–3048 mm). The program is limited to a
maximum of four pieces of busway per run and twenty pieces
per order. For complete details of the program, contact
Square D at 1-888-SQUARE D (1-888-778-2733).
— three-phase, four-wire
How To Properly Measure Your Missing Link(s)
All Missing Link dimensions should be measured to the nearest
whole inch from centerline of joint to centerline of joint, or
centerline of joint to centerline of busway.
As shown in Figure 22 Diagram A, the centerline of the joint is
located at the joint bolt on the end with a joint-pak installed. If
the joint-pak is not installed, the centerline of the joint is
one inch (25 mm) from the end of the bus bars.
If it is necessary to measure an elbow, the dimensions X and Y
(shown in Figure 22 Diagram B) are all that’s needed. Be sure
to measure from centerline of joint (as described above) to
centerline of busway housing. You must also specify whether
an edgewise or flatwise elbow is required. The table on page 49
lists the standard minimum elbow dimensions for each
amperage.
A - Straight Lengths
Without
joint pak
With
joint pak
CL
1.00
End
25
of bars
X
B - Elbows
CL
CL Bus
CL Joint Bus
X
1.00
25
Without
End
joint pak
of bars
CL Joint
bolt
With
joint pak
Y
CL Joint
Dual Dimensions: INCHES
Millimeters
Figure 22
30
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Electrical Data
Electrical Data
Impedance Values • Standards: UL857 (File Number E22182); CSA C22.2 No.
27-1973 (File Number LL-61778); IEC 439 Parts 1 and 2
Line-to-Neutral (Milliohms Per 100 Feet)
• Systems: ac–3Ø3W, 3Ø4W, 1Ø2W, 1Ø3W. All neutrals are
100% capacity dc–2-pole
• Voltage: 600 Volts ac/dc, 50 Hz and 60 Hz
• Ground: 50% capacity as standard for 800 A–5000 A, as an
option on 225 A–600 A
• Enclosure: Indoor and outdoor
Short Circuit Ratings: UL Three-cycle Test
(KA, RMS Symmetrical)
Aluminum
Ampere
Rating AOF2 AOFH2 AP
AF2
AFH2 AP2
a
Aluminum Busway
R
X60 Hz
X50 Hz
R
X60 Hz
X50 Hz
225
400
600
800
1000
7.30
3.71
2.04
2.67
2.15
3.42
2.60
1.59
.91
.74
2.85
2.17
1.32
.76
.62
4.06
2.13
2.13
1.86
1.63
3.75
2.30
2.30
1.10
.96
3.12
1.92
1.92
.92
.80
1200
1350
1600
2000
2500
1.62
1.36
1.05
.88
.71
.60
.53
.45
.37
.30
.50
.44
.37
.30
.25
1.17
1.05
.88
.78
.54
.76
.70
.61
.51
.38
.63
.58
.51
.42
.32
3000
4000
5000
.53
.41
...
.23
.14
...
.19
.12
...
.48
.35
.25
.34
.21
.17
.28
.17
.14
Impedance values are for busway operating at 80 °C (176 °F) temperature.
Copper
APH
APH2
COF2
CF2
COFH2
CFH2
CP
CP2
CPH
CPH2
Resistance Values for Aluminum Integral Ground Bus
225
400
600
...
...
...
...
...
...
22
22
22
...
42
42
...
...
...
...
...
...
22
22
22
...
42
42
Ampere Rating
3Ø3W and 3Ø4W
800
1000
1200
1350
1600
50
50
50
50
50
85
100
100
100
100
50
50
50
50
50
75
100
100
100
100
50
50
50
50
50
85
85
100
100
100
50
50
50
50
50
75
75
100
100
100
2000
2500
3000
4000
5000
100
100
100
150
...
125
125
125
200
...
150
150
150
...
...
50
100
100
150
150
65
125
125
200
200
100
150
150
...
...
150
150
150
200a
...
Copper Busway
Ampere
Rating
100
150
150
200a
200a
Certain fittings are UL Rated at 150 KA RMS Symmetrical.
Copper Phase
Conductors
225
400
600
800
1000
8.1
6.4
5.3
4.0
3.5
8.1
6.4
6.4
4.4
4.0
1200
1350
1600
2000
2500
3.2
3.0
2.8
2.2
2.0
3.5
3.4
3.0
3.0
2.2
3000
4000
5000
1.8
1.7
...
2.0
1.7
1.7
Resistance values for the integral ground bus are at 80 °C (176 °F) operating
temperature.
Short Circuit Ratings: (KA, RMS Symmetrical) (Series
Connected with a Fuse)
Aluminum
DC Resistance (Milliohms per 100 Feet)
Aluminum Phase
Conductors
Copper
Ampere
Rating
AF2
AFH2
AP
AP2
APH
APH2
CF2
CFH2
CP
CP2
CPH
CPH2
225
400
600
...
...
...
...
...
...
200
100
50
...
200
200
...
...
...
...
...
...
200
100
50
...
200
200
800
1000
1200
1350
1600
100
100c
100
100f
100
200
200c
200
200f
200
200
100c
100
100f
100
200
200c
200
200f
200
100
100c
100
100f
100
200
200c
200
200f
200
200
200c
100
100f
100
200
200c
200
200f
200
2000
2500
3000
4000
5000
...
...
...
200
...
200
...
...
...
...
200
200
200
...
...
200
200
200
...
...
...
...
...
200
200
200
200
...
...
...
100
200
200
...
...
200
200
200
...
...
c A 1200 A Fuse is used in series.
f A 1600 A Fuse is used in series.
NOTE: 225 A–600 A busway are connected in series with a
Class J or T fuse; 800 A–5000 A are connected in series with a
Class L fuse. All ratings are tested in compliance with UL/CSA
standards. All ratings apply for three-pole and four-pole busway.
31
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Electrical Data
Voltage Drop Sample Calculations (60 Hz)
Sample No. 1
Sample No. 2
1000 A aluminum busway at 50% power factor–60 Hz
1000 ampere copper busway at 50% power factor–60 Hz
Voltage Drop
Voltage Drop
=
=
√3 I (R cos Ø + X sin Ø)
√3 X 1000 (.00215 X .50 + .00074 X .866)
√3 I (R cos Ø + X sin Ø)
√3 X 1000 (.00163 X .50 + .00096 X .866)
=
=
= 2.97 Volts/100 ft - concentrated load
= 2.85 Volts/100 ft - concentrated load
= 2.85 = 1.43 Volts/100 ft - distributed load
2
Voltage Drop Data (60 Hz At Rated Load)
The values expressed below are based on a single concentrated load at the end of the busway run. For distributed loading, divide
the values shown by two (2).
Average Phase Line-To-Line Voltage Drop in Volts Per 100 ft (3048 cm)
Power Factor – Aluminum Busway
Power Factor – Copper Busway
Ampere
Rating
100
90
80
70
50
30
20
100
90
80
70
50
30
20
225
400
600
2.845
2.570
2.120
3.141
3.099
2.628
3.076
3.137
2.687
2.943
3.086
2.664
2.577
2.845
2.491
2.125
2.489
2.212
1.875
2.279
2.043
1.582
1.476
2.214
2.061
2.023
3.034
2.143
2.137
3.205
2.151
2.171
3.256
2.057
2.118
3.177
1.869
1.963
2.944
1.748
1.856
2.785
Average Phase Line-to-Line Voltage Drop in Volts Per 100 ft (3048 cm)
Aluminum Busway – Power Factor %
Ampere
Rating
100
95
90
85
80
75
70
60
50
40
30
20
800
1000
1200
1350
1600
3.700
3.724
3.367
3.180
2.910
3.908
3.938
3.588
3.408
3.154
3.879
3.910
3.574
3.402
3.162
3.809
3.841
3.519
3.356
3.130
3.716
3.748
3.442
3.288
3.076
3.609
3.641
3.350
3.205
3.007
3.490
3.522
3.248
3.111
2.927
3.229
3.260
3.018
2.899
2.744
2.942
2.972
2.764
2.663
2.535
2.636
2.664
2.490
2.408
2.307
2.313
2.340
2.200
2.136
2.063
1.975
2.001
1.895
1.850
1.804
2000
2500
3000
4000
3.048
3.074
2.754
2.841
3.296
3.326
2.989
3.001
3.302
3.333
3.000
2.979
3.266
3.298
2.970
2.925
3.208
3.239
2.920
2.854
3.134
3.165
2.856
2.772
3.049
3.080
2.781
2.681
2.854
2.884
2.608
2.480
2.634
2.662
2.412
2.260
2.394
2.420
2.197
2.025
2.137
2.162
1.966
1.777
1.866
1.888
1.722
1.518
Average Phase Line-to-Line Voltage Drop in Volts Per 100 ft (3048 cm)
Copper Busway – Power Factor %
Ampere
Rating
100
95
90
85
80
75
70
60
50
40
30
20
800
1000
1200
1350
1600
2.577
2.823
2.432
2.455
2.439
2.924
3.201
2.803
2.844
2.845
2.984
3.266
2.877
2.923
2.932
2.994
3.276
2.899
2.949
2.963
2.976
3.256
2.893
2.946
2.965
2.941
3.217
2.869
2.924
2.947
2.893
3.164
2.830
2.888
2.914
2.766
3.024
2.723
2.783
2.816
2.609
2.852
2.584
2.645
2.683
2.428
2.653
2.420
2.482
2.525
2.227
2.433
2.236
2.298
2.344
2.009
2.194
2.034
2.095
2.144
2000
2500
3000
4000
5000
2.702
2.338
2.494
2.425
2.165
3.119
2.735
2.921
2.758
2.517
3.202
2.822
3.015
2.817
2.590
3.227
2.854
3.051
2.828
2.616
3.222
2.858
3.055
2.813
2.615
3.195
2.842
3.039
2.781
2.598
3.153
2.812
3.008
2.736
2.567
3.035
2.719
2.910
2.619
2.477
2.881
2.594
2.777
2.472
2.358
2.700
2.443
2.617
2.303
2.215
2.496
2.271
2.434
2.115
2.054
2.271
2.080
2.230
1.911
1.876
Notes:
For different lengths, multiply values from 60 Hz tables by
• For balanced 3-phase line-to-line voltage drop 4-wire
busway, use values from tables.
• For balanced 3-phase line-to-neutral voltage drop, multiply
values from tables by .577.
• For single-phase voltage drop, multiply values from tables
by 1.15.
• For other than rated current, multiply values from tables by
Actual Footage
100 ft
• Voltage drop calculations for 50 Hz can be made by
substituting the appropriate “x” value from page 31 into
samples No.1 and 2 above.
• For other frequency values (e.g., 400 Hz), contact your local
Square D representative for assistance.
Actual Current
Rated Current
32
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
225 A–600 A Catalog Numbering System/Physical Data
I-LINE® Busway Catalog Numbering System
Catalog numbers are composed of two basic parts—the PREFIX (as below), plus the SUFFIX of each individual busway
component on pages 34–37.
The PREFIX contains necessary busway information except individual component descriptive details that are defined as the
SUFFIX. The catalog number PREFIX will generally remain unchanged throughout a busway run while the SUFFIX will vary with
each individual length or fitting selected.
A few devices, such as hangers, wall flanges, etc., do not follow the exact pattern described above. For these exceptions, a
complete listing of device catalog numbers is shown with the individual device drawing(s) on pages 38–40.
Bus Bar Material: A = Aluminum; C = Copper
Type of Busway:
P = Plug-in
Special Features:
H= High short circuit bracing
(Optional)
Number of Poles: 3 = 3Ø3W; 5 = 3Ø4W. 100%N
Ampere Rating:
in hundreds of amperes (e.g., 04 = 400 amperes)
Ground Bus:
(Optional)
G = 50% capacity integral ground bus
Descriptive identification of individual piece
p
A
p
P
p
H
–
Prefix
p
5
p
04
p
G
–
p
10
Suffix–of each individual busway
component drawing beginning
on page 34.
33
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
225 A–600 A Catalog Numbering System/Physical Data
Straight Lengths
17.50
24.00
445
3.31
24.00
610
24.00
610
24.00
610
6.50
610
3.19
165
81
84
Top
3.31
3.19
6.50
81
165
24.00
24.00
610
24.00
610
24.00
610
84
17.50
610
445
Front
120.00
3048
Dual Dimensions: INCHES
Millimeters
Catalog Number Suffix
-10
Standard Length –Feet
10
6
3.05
1.83
10
6
Standard Length –Meters
Number of Plug-in Openings
-6
Cross Section
Top
G
A
B
C
N
6.00
152
Dual Dimensions: INCHES
Millimeters
W
Aluminum Content and Weight
Aluminum
Ampere
Rating
225
400
600
Width
Weights
Bus Bars Per Phase
3-Pole
4-Pole
IN
mm
IN
mm
Lb/Ft
kg/m
Lb/Ft
kg/m
2.25
3.38
4.75
57
86
121
(1) .25x0.94
(1) .25x2.00
(1) .25x3.38
(1) 6x24
(1) 6x51
(1) 6x86
6.1
7.5
9.4
9.1
11.2
14.0
6.4
7.9
10.6
9.5
11.8
15.8
Copper Content and Weight
Copper
Ampere
Rating
Width
225
400
600
Weights
Bus Bars Per Phase
3-Pole
4-Pole
IN
mm
IN
mm
Lb/Ft
kg/m
Lb/Ft
kg/m
2.25
3.38
3.38
57
86
86
(1) .25x0.94
(1) .25x2.00
(1) .25x2.00
(1) 6x24
(1) 6x51
(1) 6x51
8.3
12.1
12.1
9.8
18.0
18.0
9.3
13.9
13.9
10.4
20.7
20.7
Joint Detail
Top
Top
6.50
165
2.88 18.75
73
Front
476
9.38
239
Joint CL
Top
12.25
311
Dual Dimensions: INCHES
Millimeters
Dual Dimensions: INCHES
Front
Front
Millimeters
34
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
225 A–600 A Catalog Numbering System/Physical Data
Cable Tap Boxes
nc
ara
4.29
0.56 Dia. hole
109
E
CL
B
C
B
n
nti
ou
14
e
le
gc
m
red
i
0.90
qu
Re
23
E
14.00
356
C
A
CL Plug-in
opening
7.75
D
197
CL Plug-in
opening
3.88
A
Dual Dimensions: INCHES
99
Millimeters
225 A
7.50
CL Plug-in
opening
191
D
Dual Dimensions: INCHES
400 A /600A
A
Ampere
Rating
225
400
600
IN
B
mm
IN
C
mm
IN
D
mm
IN
Eu
mm
IN
mm
16.38 416 8.42 216 3.90 100 3.30
83 9.45 267
25.95 659 18.44 468 9.76 248 7.50 191 14.00 356
25.95 659 18.44 468 9.76 248 7.50 191 14.00 356
Millimeters
Lugs Per
Phase and
Neutral
Ground
Lug
3-Pole
Weight
3Ø4W 100%N
1-300 kcmil
2-500 kcmil
2-500 kcmil
1 – #6-2/0
1 – #6-2/0-300 kcmil
1 – #6-2/0-300 kcmil
PTB-302G
PBTB-306G
PBTB-306G
18.25 lb
60.00 lb
60.00 lb
PTB-502G
PBTB-506G
PBTB-506G
Catalog Number (With Ground Bus)
Weight
19.00 lb
62.00 lb
62.00 lb
u Lugs in plug-in tap boxes can be reversed in field so that end of lugs point in opposite direction from that shown on drawing. (400 A and 600 A only.)
Tees
5.88
149
6.00
152
Top
Top
Front
8.12
206
6.88
175
Dual Dimensions: INCHES
Millimeters
Ampere Rating
(Tee Leg)
Catalog Number
(Without Ground Bus)
Catalog Number
(With Ground Bus)
Aluminum
Copper
3-Pole
3Ø4W
100% N
3-Pole
3Ø4W
100% N
225
400
...
600
225
400
600
...
PTT-2-3W
PTT-3-3WG
PTT-3-3WG
PTT-4-3WG
PTT-2-4W
PTT-3-4WG
PTT-3-4WG
PTT-4-4WG
PTT-2-3WG
PTT-3-3WG
PTT-3-3WG
PTT-4-3WG
PTT-2-4WG
PTT-3-4WG
PTT-3-4WG
PTT-4-4WG
35
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
225 A–600 A Catalog Numbering System/Physical Data
Elbows
18.00
457
Top
Top
18.00
18.00
457
457
Top
Front
Front
Dual Dimensions: INCHES
18.00
Millimeters
457
Dual Dimensions: INCHES
Millimeters
Front Inside Elbow: Catalog Number Suffix–LFI
Top Inside Elbow: Catalog Number Suffix–LTI
18.00
Top
457
18.00
Top
457
Front
18.00
Top
457
Front
Front
18.00
Dual Dimensions: INCHES
457
Millimeters
Dual Dimensions: INCHES
Millimeters
Front Outside Elbow: Catalog Number Suffix–LFO
Top Outside Elbow: Catalog Number Suffix–LTO
Expansion Fitting
Unfused Reducer
Top
A
17.20
437
18.00
457
8.13
206
15.76
914
18.00
9.40
400
Front
36.00
457
Front
239
7.63
12.00
194
305
Top
Dual Dimensions: INCHES
Millimeters
36.00
914
Catalog Number Suffix
Bolt End
Ampere Rating
60.00
1524
Note: Expansion joint permits
+
_1.5 inch (+
_ 38 mm) expansion. Use
recommended only when busway
passes through building
expansion joint.
225
400
600
Slot End Ampere Rating
225
400
600
...
-R02
-R02
...
...
q-R04
...
...
...
q Aluminum busway only.
Dual Dimensions: INCHES
Millimeters
Ampere Rating
A
Aluminum
Copper
IN
mm
225
400
...
600
225
400
600
...
4.51
5.57
5.57
6.95
114
141
141
176
NOTE: The National Electrical Code (Article 364-11) states that
overcurrent protection is required where busways are reduced in
ampacity except for certain industrial applications.
Catalog Number Suffix–EJ
36
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
225 A–600 A Catalog Numbering System/Physical Data
Flanged End Cutout And Drilling Template
12.00
305
W
Top
0.50
0.50
V
13
0.38
13
10
3.69
Top
94
Front
11.62
5.00
295
127
H
Neutral
Neutral
Millimeters
Aluminum Copper
94
W
V
CL
0.38
Catalog Number Suffix–FES 12 (Slot End) /FEB 12 (Bolt End)
H
3.69
Cutout
Dual Dimensions: INCHES
Flanged End
Ampere Rating
H
Flanged
collar
T
10
T
0.31 Dia. hole
8
(6 Holes)
W
IN
mm
IN
mm
IN
mm
IN
mm
225
225
13.38
340
4.44
113
2.44
62
3.44
87
400
400
13.38
340
5.50
140
3.50
89
4.50
114
...
600
13.38
340
5.50
140
3.50
89
4.50
114
600
...
13.38
340
6.88
175
4.88
124
5.88
149
Flanged Collar
Dual Dimensions: INCHES
Millimeters
Flanged End Details
Ampere Rating
7.00
5.00
178
127
2.00
225
400
2.00
Contact
surface
51
A
225
Contact
102 surface
51
A
Figure 1
A
Fig.
IN
mm
1
0.94
24
400
2
2.00
51
...
600
2
2.00
51
600
...
2
3.38
86
Figure 2
CL
CL
Top
Top
A
G
25
Copper
4.00
C
B
1.00
Aluminum
5/16- 16 x 1.00
Hex head bolt
C
B
G
A
G
C
B
A
C
0.25
B
CL
A
6
5.12
Flanged collar
3.00 3.00
3.00 3.00
3-Pole
3-Pole with Ground Bus
CL
Millimeters
CL
Top
3-Pole with Ground Bus
76
(Bottom View)
Top
A
G
Dual Dimensions: INCHES
76
76
N
C
B
76
125
CL
0.12
3
N
C
B
A
G
G
N
C
B
A
N
C
B
CL
A
5.12
Flanged collar
3.00 3.00 3.00
3.00 3.00 3.00
4-Pole
4-Pole with Ground Bus
76
76
76
76
76
76
CL
125
4-Pole with Ground Bus
(Bottom View)
37
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
225 A–600 A Catalog Numbering System/Physical Data
Flatwise Hanger
0.56 Dia. hole
14
0.62
16
B
Drop rod by customer
2.00
A
51
0.25
6
2.12
54
Ampere Rating
A
B
Aluminum
Copper
IN
mm
IN
mm
Catalog
Number
225
400
...
600
225
400
600
...
2.65
3.71
3.71
5.09
67
94
94
129
1.06
1.44
1.44
2.82
27
36
36
72
HP-2-F
HP-3-F
HP-3-F
HP-5-F
5.50
140
CL
Dual Dimensions: INCHES
Millimeters
Edgewise Hanger
0.62 Dia. hole
16
6.44
163
1.90
Drop rod
by customer
1.87
47
48
0.88
22
B
A
CL
Ampere Rating
Aluminum
225a
400
...
600
Copper
225a
400
600
...
A
B
IN
mm
IN
mm
Catalog
Number
6.29
6.29
6.29
7.67
160
160
160
195
3.57
3.57
3.57
4.26
91
91
91
108
HP-3-E
HP-3-E
HP-3-E
HP-5-E
Dual Dimensions: INCHES
Millimeters
1.50
38
aHanger spacing on 5 foot centers maximum when mounted edgewise.
Sway Brace Collar
Sway braces are used when only one side of the busway is
heavily loaded with tap-off units or when other factors could
cause possible swaying of the busway.
Building
support
Catalog Number HP-1-SBC
0.50 Drop rod
13 and beam clamp
by customer
Sway brace
(As required)
by customer
4.62
117
Note: When required, the
recommended spacing is
20 foot (610 cm) centers.
8.00
203
Dual Dimensions: INCHES
Millimeters
38
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
225 A–600 A Catalog Numbering System/Physical Data
Top
Vertical Hanger
To secure hanger to
busway, attach mounting
screw on bottom of busway
to hanger brace through slot.
1.12
3.18
81
28
4.30
A
109
Customer to locate and drill
four (4) .31-inch (8 mm) diameter holes
for securing mounting
channel to hanger.
B
Top
Bottom
Channel iron and
.50-inch (13 mm) diameter bolts
by customer.
CL Joint
9.38
11.50
238
Floor
level
292
Note: Waterproof curbing
is required around floor
opening shown.
.75-inch (19 mm) diameter holes for access
to mounting screw on busway when securing
hanger to busway mounting.
2.12
54
Dual Dimensions: INCHES
Millimeters
Ampere Rating
A
B
Aluminum
Copper
IN
mm
IN
mm
Catalog
Number
225
400
...
600
225
400
600
...
4.28
5.32
5.32
6.70
109
135
135
170
6.54
7.58
7.58
8.96
166
192
192
228
HP-2-V
HP-3-V
HP-3-V
HP-4-V
Note: Dimensions shown apply for 6 ft (183 cm) and 10 ft (305 cm) straight lengths only.
Consult your local Square D sales office for dimensions that apply for fractional
straight lengths.
Top
Vertical Spring Hanger
1.12
CL
Joint
28
1.12
28
4.32 4.32
110
Top
110
CL Joint
Bottom
A
9.38
To secure hanger to busway,
attach mounting screw on
bottom of busway,
to hanger brace.
238
B
17.69
449
8.31
211
Channel iron and 0.50-inch (13 mm)
diameter bolts by customer.
Note: With springs properly
adjusted, the busway weight Floor
level
will be distributed equally on
each floor.
Ampere Rating
A
B
Customer to locate and drill four
(4) 0.31-inch (8 mm) diameter
holes for securing mounting channel
to hanger.
0.75-inch (19 mm) diameter holes
for access to mounting screw on
busway when securing hanger to
busway housing.
Aluminum
Copper
IN
mm
IN
mm
Catalog
Number
225
400
...
600
225
400
600
...
4.28
5.32
5.32
6.70
109
135
135
170
6.54
7.58
7.58
8.96
166
192
192
228
HP-2-VS
HP-3-VS
HP-3-VS
HP-4-VS
Note: Dimensions shown apply for 6 ft (183 cm) and 10 ft (305 cm) straight lengths only.
Consult your local Square D sales office for dimensions that apply for other
straight lengths.
39
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
225 A–600 A Catalog Numbering System/Physical Data
End Closure
6.10
155
Ampere Rating
A
Aluminum
Copper
IN
mm
Catalog
Number
225
400
...
600
225
400
600
...
2.66
3.52
3.52
4.90
68
89
89
124
ACP-2-EC
ACP-3-EC
ACP-3-EC
ACP-4-EC
Joint
CL
3.95
100
A
Dual Dimensions: INCHES
Millimeters
Wall And Floor Flange
Dual Dimensions: INCHES
Millimeters
Ampere Rating
A
2.00
B
2.00
51
3.00
51
2.06
Catalog Number
IN
mm
IN
mm
Wall Flange Floor Flange
225
400
...
600
225
400
600
...
6.28
7.34
7.34
8.72
160
186
186
221
8.34
9.40
9.40
10.78
212
239
239
274
ACP-2-WF
ACP-3-WF
ACP-3-WF
ACP-4WF
76
2.06
52
B
Copper
3.00
76
A
Aluminum
ACP-2-FF
ACP-3-FF
ACP-3-FF
ACP-4-FF
52
10.00
10.00
254
254
2.06
2.06
52
52
Wall Flange
Floor Flange
Required Wall Openings
W
Y
Ampere Rating
Aluminum
Copper
Straight
Length
Y★
W
Flatwise Elbow
Edgewise Elbow
Flanged Ends
Wall Thickness
Y★
W
W
4 IN
102 mm
8 IN
203 mm
12 IN
305 mm
8 IN
203 mm
10 IN
254 mm
12 IN
305 mm
9 IN
229 mm
11 IN
279 mm
9 IN
229 mm
11 IN
279 mm
16 IN
406 mm
Wall Thickness
20 IN
508 mm
24 IN
610 mm
14 IN
356 mm
16 IN
406 mm
18 IN
457 mm
6 IN
152 mm
13 IN
330 mm
15 IN
381 mm
17 IN
432 mm
19 IN
483 mm
7 IN
178 mm
11 IN
279 mm
13 IN
330 mm
15 IN
381 mm
17 IN
432 mm
19 IN
483 mm
7 IN
178 mm
13 IN
330 mm
15 IN
381 mm
17 IN
432 mm
19 IN
483 mm
21 IN
533 mm
8 IN
203 mm
Y★
4 IN
102 mm
8 IN
203 mm
12 IN
305 mm
Y★
225
225
6 IN
152 mm
400
400
7 IN
178 mm
—
600
7 IN
178 mm
600
—
8 IN
203 mm
6 IN
152 mm
8 IN
203 mm
7 IN
178 mm
7 IN
178 mm
8 IN
203 mm
15 IN
381 mm
8 IN
203 mm
16 IN
406 mm
20 IN
508 mm
24 IN
610 mm
21 IN
533 mm
23 IN
584 mm
W
13 IN
330 mm
15 IN
381 mm
17 IN
432 mm
19 IN
483 mm
★ Dimension allows clearance for vertical hanger. Subtract one inch (25 mm) for horizontal mounted busway.
40
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Busway Catalog Numbering System
Catalog numbers are composed of two basic parts—the PREFIX (as below), plus the SUFFIX of each individual busway
component on pages 43–55.
The PREFIX contains necessary busway information except individual component descriptive details that are defined as the
SUFFIX. The catalog number PREFIX will generally remain unchanged throughout a busway run while the SUFFIX will vary with
each individual length or fitting selected.
A few devices, such as hangers, wall flanges, etc., do not follow the exact pattern described above. For these exceptions, a
complete listing of device catalog numbers is shown with the individual device drawing(s) on pages 56–57.
2 = I-LINE II busway
designation
Number of Poles:
3 = 3Ø3W; 5 = 3Ø4W. 100%N
Special Features: (Optional)
F = Feeder (Outdoor only)
H = High short circuit bracing
Ampere Rating:
in hundreds of amperes
(e.g., 20 = 2000 amperes)
Type of Busway:
F = Feeder; P = Plug-In,
O = Outdoor; R = Riser Plug-In
Ground Bus:
G = 50% capacity integral ground bus
Bus Bar Material:
A = Aluminum, C = Copper
Descriptive identification
of individual piece
p
p
p
p
A
P
H
2
–
PREFIX
p
p
p
p
5
20
G
10ST
SUFFIX of
each individual
busway component
beginning
on page 43.
41
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Cross Sections—Plug-In and Indoor Feeder Lengths
Dual Dimensions: INCHES
Millimeters
G
A
B
C
N
G
Top
5.88
149
Top
G
A
B
C
N
G
G
A
B
C
N
G
Top
W
W
W
Figure A
Figure B
Figure C
Cross Sections—Fittings and All Outdoor Feeder
1.20
Dual Dimensions: INCHES
Nominal clearance
(Typical)
30
Millimeters
1.20
30
5.88
149
.25
.25
W
6
6
.25
.25 .25
W
6
6
Figure B
Figure A
.25
W
6
6
Figure C
Note: Dotted line indicates the profile of the joint covers for Outdoor Feeder busway. The profile for indoor fittings is the same as the busway itself.
Aluminum Content and Weight
W
Ampere
Rating
Fig.
Bus Bars Per Phase
IN
mm
IN
800
1000
1200
1350
1600
4.34
5.34
6.34
7.34
8.84
110
136
161
186
225
A
A
A
A
A
One – .25 x 3.00
One – .25 x 4.00
One – .25 x 5.00
One – .25 x 6.00
One – .25 x 7.50
2000
2500
3000
12.72
16.22
18.72
323
412
475
B
B
B
4000
25.60
650
C
mm
Weights—Feeder
3-Pole
Weights—Plug-In
4-Pole
3-Pole
4-Pole
Lb/Ft
Kg/M
Lb/Ft
Kg/M
Lb/Ft
Kg/M
Lb/Ft
Kg/M
One – 6 x 76
One – 6 x 102
One – 6 x 127
One – 6 x 152
One – 6 x 191
9.1
10.1
11.1
12.1
13.8
13.5
15.0
16.5
18.0
20.5
10.0
11.3
12.5
13.8
15.8
14.9
16.8
18.6
20.5
23.5
11.2
12.2
13.2
14.2
15.9
16.7
18.2
19.6
21.1
23.7
12.1
13.4
14.6
15.9
17.9
18.0
19.9
21.7
23.7
26.6
Two – .25 x 4.50
Two – .25 x 6.00
Two – .25 x 7.50
Two – 6 x 114
Two – 6 x 152
Two – 6 x 191
19.1
22.1
25.1
28.4
32.9
37.3
22.5
26.7
30.6
33.5
39.7
45.5
21.2
24.2
27.2
31.5
36.0
40.5
24.6
26.8
32.7
36.6
39.9
48.7
Three – .25 x 6.50
Three – 6 x 165
33.9
50.4
40.4
60.1
36.0
53.6
42.5
63.2
Copper Content and Weight
W
Ampere
Rating
Fig.
Bus Bars Per Phase
IN
mm
IN
800
1000
1200
1350
1600
2000
3.84
4.34
5.34
5.84
6.74
7.84
98
110
136
148
171
199
A
A
A
A
A
A
One – .25 x 2.50
One – .25 x 3.00
One – .25 x 4.00
One – .25 x 4.50
One – .25 x 5.40
One – .25 x 6.50
2500
3000
12.72
15.22
323
387
B
B
4000
5000
23.60
25.10
599
638
C
C
mm
Weights—Feeder
3-Pole
Weights–Plug-In
4-Pole
3-Pole
4-Pole
Lb/Ft
Kg/M
Lb/Ft
Kg/M
Lb/Ft
Kg/M
Lb/Ft
Kg/M
One – 6 x 64
One – 6 x 76
One – 6 x 102
One – 6 x 114
One – 6 x 137
One – 6 x 165
12.1
13.8
16.8
18.3
21.1
24.3
18.0
20.5
25.0
27.2
31.4
36.2
14.6
16.7
20.8
22.8
27.5
30.8
21.7
24.9
31.0
33.9
40.9
45.8
14.2
15.9
18.9
20.4
23.2
26.4
21.1
23.7
28.1
30.4
34.5
39.3
16.7
18.8
22.9
24.9
29.6
32.9
24.8
28.0
34.1
37.1
44.0
49.0
Two – .25 x 4.50
Two – .25 x 5.00
Two – 6 x 114
Two – 6 x 127
38.7
42.7
57.6
63.5
47.7
51.7
71.0
76.9
40.8
44.8
60.7
65.2
49.8
53.8
74.1
80.1
Three – .25 x 4.50
Three – .25 x 6.00
Three – 6 x 114
Three – 6 x 152
59.1
72.6
87.9
108.0
72.6
90.6
108.0
134.8
61.2
74.7
91.1
111.2
74.7
92.7
111.2
137.9
Note: For required wall and floor openings, refer to page 40.
42
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Straight Lengths—Feeder
120.00
3048
Note: All straight lengths and fittings of feeder busway are fully compatible,
rating for rating, with straight lengths of plug-in busway. Available in 1-in.
(25 mm) increments from 16–120 in. (406–3048 mm).
Dual Dimensions: INCHES
Millimeters
Straight Lengths—Plug-in (Indoor Only)
Sq
uare
D
Com
pany
12.00
To
p
305
Sq
uare
D
Com
pany
24.00
610
To
p
Sq
uare
D
Com
pany
24.00
610
To
p
Squ
are
D
120.00
3048
Co
mp
any
24.00
610
To
p
Sq
uar
eD
Co
mpa
ny
24.00
610
Note: All straight lengths of plug-in busway are fully compatible, rating for rating,
with straight lengths and fittings of feeder busway.
12.00
305
Dual Dimensions: INCHES
Millimeters
Catalog Number Suffix
-10ST
-8ST
-6ST
-4ST
Standard Lengths–Feet
Standard Lengths–Meters
Number of Plug-in Openings
10 ft
3.05 m
10
8 ft
2.44 m
8
6 ft
1.83 m
6
4 ft
1.219 m
4
43
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Qwik Flange (Indoor Only)
X
Z
X
Y
Y
Catalog Number Suffix –QF
Amperage Ratings
X
3-Pole
Y
4-Pole
Z
Aluminum
Copper
IN
mm
IN
mm
IN
mm
IN
mm
...
800
1000
...
1200
800
1000
1200
1350
...
10.50
10.50
10.50
10.50
10.50
207
207
207
207
207
10.50
10.50
10.50
10.50
10.50
207
207
207
207
207
16.26
16.26
16.26
16.26
16.26
413
413
413
413
413
7.50
7.50
7.50
7.50
7.50
190
190
190
190
190
...
1350
...
1600
2000
2500
1600
...
2000
...
2500
...
10.50
10.50
10.50
10.50
14.34
17.84
207
207
207
207
364
453
10.50
10.50
10.50
10.50
14.34
17.84
207
207
207
207
364
453
16.26
16.26
16.26
16.26
16.26
16.26
413
413
413
413
413
413
7.50
7.50
7.50
7.50
7.50
7.50
190
190
190
190
190
190
...
3000
...
4000
...
3000
...
4000
...
5000
16.84
20.34
25.22
27.22
26.72
428
517
641
691
679
16.84
20.34
25.22
27.22
26.72
428
517
641
691
679
16.26
16.26
16.26
16.26
16.26
413
413
413
413
413
7.50
7.50
7.50
7.50
7.50
190
190
190
190
190
44
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Qwik Flange (Indoor Only)
Dual Dimensions: INCHES
Millimeters
CL
2.79
71 1.25
32
A
Aluminum
Ampere Rating
Fig.
800
1000
1200
1350
1600
2000
2500
3000
4000
A
A
C
A
Figure 1
A
Figure 2
Figure 3
B
C
mm
IN
mm
IN
mm
Copper
Ampere Rating
Fig.
1
1
1
1
1
3.00
4.00
5.00
6.00
7.50
76
102
127
152
191
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
800
1000
1200
1350
1600
2
2
2
3
4.50
6.00
7.50
6.50
114
152
191
165
11.38
14.88
17.38
24.26
289
378
441
616
2.38
2.88
2.38
2.38
60
73
60
60
2000
2500
3000
4000
5000
A
102
4.00
C
mm
IN
mm
IN
mm
1
1
1
1
1
2.50
3.00
4.00
4.50
5.40
64
76
102
114
137
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
2
3
3
6.50
4.50
5.00
4.50
6.00
165
114
127
114
152
...
11.38
13.88
22.26
23.76
...
289
353
565
604
...
2.38
3.88
4.38
2.88
...
60
86
111
73
102
4.00
B
IN
4.00
102
A
C
B
IN
4.00
A
C
B
4.00
102
Dual Dimensions: INCHES
102
Millimeters
NOTE: Refer to “Detail of Phase Bussing Connections in a
Switchboard” on page 48.
45
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Flanged End
0.62
0.62
G
16
16
0.88
22
E
F
J
Dual Dimensions: INCHES
102
Millimeters
F
Cutout
10.00
W
Flanged
collar
E
0.88
254
K
4.00
22
B
Flanged End: Catalog Number Suffix–10 FEB
C
D
D
0.31 Dia. hole
8
(Holes)
B
C
A
Flanged
H
collar
Flanged Collar and Cutout Dimensions
Ampere Rating
L
W
H
3-Pole
G
4-Pole
J
Aluminum
Copper
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
...
800
...
1000
1200
800
1000
1200
1350
...
10.00
10.00
10.00
10.00
10.00
254
254
254
254
254
7.38
7.38
8.00
9.00
10.00
187
187
203
229
254
12.82
12.82
12.82
12.82
12.82
326
326
326
326
326
13.18
13.18
13.18
13.18
13.18
335
335
335
335
335
5.12
5.12
5.76
6.75
7.76
130
130
145
171
196
10.00
10.00
10.00
10.00
10.00
254
254
254
254
254
1350
1600
2000
2500
3000
1600
2000
2500
3000
...
10.00
10.00
10.00
10.00
10.00
254
254
254
254
254
11.00
13.88
15.88
19.88
22.75
279
352
403
505
578
12.82
18.82
18.82
18.82
18.82
326
478
478
478
478
13.18
19.18
19.18
19.18
19.18
335
487
487
487
487
8.75
11.63
13.63
17.63
20.50
222
295
346
448
521
10.00
16.00
16.00
16.00
16.00
254
406
406
406
406
4000
...
4000
5000
10.00
10.00
254
254
28.75
28.75
730
730
18.82
18.82
478
478
19.18
19.18
487
487
26.50
26.50
673
673
16.00
16.00
406
406
Flanged Collar Hole Location and Spacing
Ampere Rating
Hole Location and Spacing
N
Holes
Aluminum Copper
A
B
C
D
K
E
F
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
...
800
...
1000
1200
800
1000
1200
1350
...
10
10
10
10
10
6.38
6.38
7.00
8.00
9.00
162
162
178
203
229
3.19
3.19
3.50
4.00
4.50
81
81
89
102
114
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
11.75
11.75
11.75
11.75
11.75
296
296
296
296
296
3.88
3.88
3.88
3.88
3.88
98
98
98
98
98
...
...
...
...
...
...
...
...
...
...
1350
1600
2000
2500
3000
1600
2000
2500
3000
...
10
16
16
18
20
10.00
12.88
14.88
18.88
21.75
254
327
378
480
552
5.00
4.25
5.00
4.75
4.38
127
108
127
121
111
...
...
...
4.69
4.37
...
...
...
119
111
...
...
...
...
...
...
...
...
...
...
11.75
17.75
17.75
17.75
17.75
296
451
451
451
451
3.88
3.46
3.46
3.46
3.46
98
88
88
88
88
...
3.42
3.42
3.42
3.42
...
87
87
87
87
4000
...
4000
5000
22
22
27.75
27.75
705
705
4.62
4.62
117
117
4.63
4.63
118
118
4.63
4.63
118
118
17.75
17.75
451
451
3.46
3.46
88
88
3.42
3.42
87
87
46
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Flanged End
Dual Dimensions: INCHES
Millimeters
CL
7.00
178
Contact
102 surface
4.00
2.00
51
A
.62 Dia. hole
16
A
C
Figure 1
Aluminum
Ampere Rating
Fig.
800
1000
1200
1350
1600
2000
2500
3000
4000
A
A
A
C
B
B
Figure 3
B
C
mm
IN
mm
IN
mm
Copper
Ampere Rating
Fig.
1
1
1
1
1
3.00
4.00
5.00
6.00
7.50
76
102
127
152
191
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
800
1000
1200
1350
1600
2
2
2
3
4.50
6.00
7.50
6.50
114
152
191
165
11.38
14.88
17.38
24.26
289
378
441
616
2.38
2.88
2.38
2.38
60
73
60
60
2000
2500
3000
4000
5000
S
C
Figure 2
IN
Ampere Rating
A
T
A
A
B
C
IN
mm
IN
mm
IN
mm
1
1
1
1
1
2.50
3.00
4.00
4.50
5.40
64
76
102
114
137
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
2
3
3
6.50
4.50
5.00
4.50
6.00
165
114
127
114
152
...
11.38
13.88
22.26
23.76
...
289
353
565
604
...
2.38
3.88
4.38
2.88
...
60
99
111
73
U
Aluminum
Copper
IN
mm
IN
mm
IN
mm
...
800
...
1000
1200
800
1000
1200
1350
...
3.00
3.00
3.00
3.00
3.00
76
76
76
76
76
3.62
3.62
3.62
3.62
3.62
92
92
92
92
92
3.81
3.81
3.81
3.81
3.81
97
97
97
97
97
1350
1600
2000
2500
3000
1600
2000
2500
3000
...
3.00
3.00
5.00
5.00
5.00
76
76
127
127
127
3.62
6.62
6.62
6.62
6.62
92
169
169
169
169
3.81
6.81
6.81
6.81
6.81
97
173
173
173
173
4000
...
4000
5000
5.00
5.00
127
127
6.62
6.62
169
169
6.81
6.81
173
173
Dual Dimensions: INCHES
Millimeters
GCBAG
GNCBAG
3/8-16 x 1.00
Hex head bolt
G
G
NOTE: Refer to “Detail of Phase Bussing Connections in a
Switchboard” on page 48.
S
.12
3
G
S
G
S
4-Pole
3-Pole
Flanged collar
G C
B
A
Flanged collar
G
N
G C
B A G
CL
1.88
48
CL
CL
T
S
S
T
U
U
Dual Dimensions: INCHES
3-Pole
4-Pole
Millimeters
(Bottom View)
(Bottom View)
47
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Qwik Flange And Flanged End Termination Details
CAUTION
HAZARD OF EQUIPMENT DAMAGE
Improper contact pressure can cause overheating and
equipment failure. Use 3-inch (76 mm) conical washers and
Grade 5 hardware to ensure proper contact pressure.
E
E
Failure to follow this instruction can result in equipment damage.
Detail of Phase Bussing Connections in a Switchboard
Busway flanged end
or quik flange
Tie connector
(Used on 2 and 3 stack
configurations only)
Grade 5 hardware
Large conical washers
Switchboard bussing
48
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Elbows
tC
Join L
Dual Dimensions: INCHES
Flatwise Elbows
Millimeters
Ampere Rating
Aluminum
Copper
...
800
800
1000
1000
1200
1200
1350
...
1600
1350
2000
1600
...
2000
2500
...
3000
2500
...
3000
...
...
4000
...
5000
4000
...
Joint L Min.
CL
11.00
279
Min.
11.00
L Min.
279
Min.
Flatwise
Edgewise: Catalog Number
Suffix–LEM11
Flatwise: Catalog Number
Suffix–LFM
L
IN
11.00
11.00
12.00
12.00
12.00
13.00
13.00
15.00
16.00
17.00
18.00
21.00
21.00
22.00
mm
279
279
305
305
305
330
330
381
406
432
457
533
533
559
Catalog Number
Suffux
-LFM11
-LFM11
-LFM12
-LFM12
-LFM12
-LFM13
-LFM13
-LFM15
-LFM16
-LFM17
-LFM18
-LFM21
-LFM21
-LFM22
Offset Elbows
Flatwise Offset
tC
Join L
11.00
Ampere Rating
Aluminum
Copper
800
800/1000
1000
1200
...
1350
1200
1600
1350
...
...
2000
1600
...
2000
2500
2500
...
...
3000
3000
...
4000
...
...
4000
...
5000
279
Min.
6.00
150
Min.
Dual Dimensions: INCHES
Millimeters
Edgewise: Catalog Number
Suffix–OE
11.00
279
Min.
tC
Join L
L
IN
11.00
12.00
12.00
12.00
13.00
13.00
13.00
15.00
17.00
16.00
18.00
22.00
21.00
21.00
W
mm
279
305
305
305
330
330
330
381
432
406
457
559
533
533
IN
4.00
4.00
4.00
6.00
9.00
9.00
10.00
14.00
16.00
16.00
18.00
25.00
23.00
25.00
mm
100
100
100
150
229
229
254
356
406
406
457
635
635
635
L Min.
L Min.
W Min.
Flatwise: Catalog Number Suffix–OF
Double Elbows
L Min.
L Min.
Joint
CL Joint
CL
W Min.
Ampere Rating
Dual Dimensions: INCHES
Millimeters
W Min.
11.00
279
Min.
Catalog Number Suffix–DL
L
W
Aluminum
Copper
IN
mm
IN
mm
800
1000
...
1200
1350
800/1000
1200
1350
1600
...
11.00
12.00
12.00
12.00
13.00
279
305
305
305
330
7.00
8.00
8.00
8.00
9.00
178
203
203
203
229
...
1600
2000
2500
...
2000
...
2500
...
3000
13.00
13.00
15.00
17.00
16.00
330
330
381
432
406
9.00
9.00
12.00
14.00
13.00
229
229
305
356
330
3000
4000
...
...
...
...
4000
5000
18.00
22.00
21.00
21.00
457
559
533
533
15.00
19.00
18.00
19.00
381
635
457
635
11.00 279
Min.
Catalog Number Suffix–DR
49
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Cable Tap Box–End
Ampere Rating
Dual Dimensions: INCHES
A
Ba
C
Millimeters
B
500
kcmil
Ground Lugs
Copper
IN
mm
IN
mm
IN
mm
800
1000
1200
1350
1600
800
1000
1200
1350
1600
29.14
29.14
29.14
29.14
29.14
740
740
740
740
740
11.00
11.00
11.00
14.88
14.88
279
279
279
378
378
16.00
16.00
16.00
16.00
16.00
406
406
406
406
406
3
4
4
5
6
3
4
4
5
6
...
...
...
...
...
...
2000
2500
...
3000
2000
...
2500
3000
...
29.14
29.14
39.38
39.38
39.38
740
740
1000
1000
1000
14.88
16.88
20.88
20.88
23.76
378
429
530
530
604
16.00
16.00
26.00
26.00
26.00
406
406
660
660
660
7
7
9
10
10
7
7
...
...
...
...
...
9
10
10
4000
...
4000
5000
39.38
39.38
1000
1000
29.76
29.76
756
756
26.00
26.00
660
660
14
17
...
...
14
17
28.00
10.00
254
C
Catalog Number Suffix–ETBMB
#6-300
kcmil
Aluminum
A
711
Lugs Per
Phase
and Neutral
2/0-500 kcmil
This dimension increases by 7 inches (178 mm) for outdoor end tap boxes.
a
Cable Tap Box–Center
Ampere Rating
B
Aluminum Copper
A
C
28.00
711
D
48.00
A
B
C
D
IN
mm
IN
mm
IN
mm
IN
Lugs Per
Ground Lugs
Phase
mm and Neutral #6-300 500
2/0-500 kcmil kcmil kcmil
800
1000
1200
1350
1600
800
1000
1200
1350
1600
35.00
35.00
35.00
35.00
35.00
889
889
889
889
889
14.00
14.00
14.00
14.00
14.00
356
356
356
356
356
16.00
16.00
16.00
16.00
16.00
406
406
406
406
406
7.27
7.27
7.27
7.27
7.27
185
185
185
185
185
3
4
4
5
6
3
4
4
5
6
...
...
...
...
...
...
2000
...
2500
3000
2000
...
2500
...
3000
35.00
41.70
41.70
41.70
60.00
889
1059
1059
1059
1524
14.00
20.00
20.00
20.00
22.00
356
508
508
508
559
16.00
17.60
17.60
17.60
26.00
406
447
447
447
660
7.27
10.28
12.56
12.56
16.00
185
261
319
319
406
7
7
9
9
10
7
7
...
...
...
...
...
9
9
10
4000
...
4000
5000
63.00
63.00
1600
1600
32.00
32.00
813
813
26.00
26.00
660
660
19.00
19.00
483
483
14
17
...
...
14
17
1219
Dual Dimensions: INCHES
Millimeters
Catalog Number Suffix–CTB
Cable Tap Box–Bolt On
Millimeters
24.00
10.50
~
267
28.20
Ground Lugs
76
CL
15.00
4.00
381
102
1.62
41
9.00
229
864
(Hanger width)
23.50
597
Catalog Number
800
1000
1200
1350
1600
6-500 kcmil
2-500 kcmil
3Ø3Wq
3Ø4Wq
PTB316G__j PTB516G__j
Box–can be moved to opposite end in field. 20.2-inch (513 mm) clearance
required from CL of busway, for mounting bolt-on tap boxes when box is on
top; and 10.0-inch (254 mm) required mounting clearance when box is on
the bottom.
716
CL
34.00
Lugs Per
Phase and
Neutral
Box
610
3.00
Ampere Rating
Dual Dimensions: INCHES
Drop rods
by customer
q May be used only on plug-in busway with the same number of poles.( e.g.,
do not use 3-pole units on 3Ø4W busway or 3Ø4W units on 3-pole busway.)
Cannot be mounted in the last opening on either side of a busway run.
j
Cannot be used on 800 A Copper I-LINE II busway.
Note:Add “H” on the end of the catalog number for units that will be
mounted horizontally and “V” for units that will be mounted
vertically. These mounting frames are NOT interchangeable.
4.00
102
50
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Unfused Reducer (Indoor Only)
Catalog Number Suffix
Bolt End
Ampere
Rating
12.00
305
24.00
610
12.00
305
Dual Dimensions: INCHES
Millimeters
Slot End Ampere Rating
400
600
800
800
1000
1200
1350
1600
-R04
-R04
-R04
...
...
-R06
-R06
-R06
-R06
-R06
...
...
...
...
-R08 . . .
...
...
-R08 -R10 . . .
...
-R08 -R10 -R12 . . .
-R08 -R10 -R12 -R13
1000 1200 1350 1600 2000 2500 3000
2000
2500
3000
4000
5000
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
-R08 -R10 -R12 -R13 -R16 . . .
...
...
. . . -R10 -R12 -R13 -R16 -R20 . . .
...
. . . -R10 -R12 -R13 -R16 -R20 -R25 . . .
...
...
...
. . . -R16 -R20 -R25 -R30
...
...
...
...
. . . -R20 -R25 -R30
Note: The National Electrical Code (Article 364-11) states that overcurrent
protection is required where busways are reduced in ampacity except for
certain industrial applications.
Expansion Fitting (Indoor Only)
Dual Dimensions: INCHES
Millimeters
W
Aluminum
Copper
800
1000
1200
1350
1600
...
2000
2500
3000
4000
...
W
IN
mm
800
1000
1200
1350
1600
13.50
13.50
13.50
17.38
17.38
343
343
343
441
441
2000
2500
3000
...
4000
5000
17.38
19.38
23.38
26.25
32.25
32.25
441
492
594
667
819
819
Note: Expansion joint permits 1.50 inches (38 mm) of expansion or
contraction.
Note: An expansion fitting should be used under the following conditions:
whenever a busway run crosses a building expansion. When a long
straight run of busway does not contain any elbows, or both ends of the
run are fixed.
20.00
508
40.00
1016
Catalog Number Suffix–40EJ
Tees
Ampere Rating
L
L
L
q
Aluminum
Copper
IN
L
mm
Catalog
Number
Suffix
...
800
1000
1200
...
800
1000
1200
1350
1600
11.00
11.00
12.00
12.00
12.00
279
279
305
305
305
-33TFS11B11S11
-33TFS11B11S11
-36TFS12B12S12
-36TFS12B12S12
-36TFS12B12S12
1350
1600
2000
...
2500
2000
...
2500
3000
...
13.00
13.00
15.00q
16.00q
17.00q
330
330
381q
406q
432q
-39TFS13B13S13
-39TFS13B13S13
-45TFS15B15S15
-48TFS16B16S16
-51TFS17B17S17
3000
...
...
4000
...
4000
5000
...
18.00q
21.00q
21.00q
22.00q
457q
533q
533q
559q
-54TFS18B18S18
-63TFS21B21S21
-63TFS21B21S21
-66TFS22B22S22
Add 1 inch (25 mm) for L Dimensions of outdoor tees.
51
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Service Head Flatwise
A
Top
A
Top
64.00
1626
71.00
1803
15.00
381
15.00
381
1.10
Insulating bottom
plate–removable
914
28
914
28
36.00
1.10
36.00
15.00
381
Insulating bottom
plate–removable
Dual Dimensions: INCHES
Dual Dimensions: INCHES
Millimeters
Millimeters
Catalog Number Suffix–71 SB
Catalog Number Suffix–79 LESBS15T64
Ampere
Rating
A
800
1000
1200
1350
1600
Housing
Width
Plus
2.23
57
2000
2500
3000
4000
5000
Lugs Per
Phase and Neutral
2/0-500 kcmil
Ground Lugs
#6-300 kcmil
2
3
4
4
4
2
3
3
3
4
5
7
8
10
13
5
6
7
9
11
Transformer Tap (One 3Ø Transformer)
4.50
31.50
800 9.00
229
9.00
64.00
1626
4.50
31.50
800 9.00
229
9.00
71.00
1803
9.00
229
9.00
115
229
115
Housing
width
Top
229
32.50
Housing
width
Top
826
229
39.00
1003
11.00
279
11.00
Dual Dimensions: INCHES
15.00
279
Millimeters
381
Dual Dimensions: INCHES
Millimeters
Catalog Number Suffix–71 SF
Catalog Number Suffix–79 LESFS15T64
Service Entrance devices may be ordered with an indoor type joint connection for those applications where the service head is
outdoors and penetrates a wall such that the first joint is indoors. Service Entrance devices come standard with an outdoor type
joint connection.
52
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Service Head Vertical
Ampere
Rating
Dual Dimensions: INCHES
Millimeters
28.00
Top
711
A
800
1000
1200
1350
1600
Top
29.00
15.00
26.00
660
1.10
28
A
Insulating
bottom plate
removable
Ground Lugs
#6-300 kcmil
2
3
4
4
4
2
3
3
3
4
5
7
8
10
13
5
6
7
9
11
Housing
Width
Plus
2.23
57
2000
2500
3000
4000
5000
737
381
Lugs Per
Phase and Neutral
2/0-500 kcmil
Notes:
1. Vertical service heads must be braced or supported near top, to withstand
weight of cables, ice, wind, etc.
2. Refer to NEC Article 230-24 for required clearance of service drops over roof
overhang or the ground.
4.50 Typical
115
Catalog Number Suffix–29 SV
Straight Length With Flanged Collar
Ampere Rating
IN
mm
IN
mm
...
800
...
1000
1200
800
1000
1200
1350
...
9.38
9.38
11.00
11.00
12.00
238
238
279
279
305
13.18
13.18
13.18
13.18
13.18
335
335
335
335
335
1350
1600
2000
2500
3000
1600
2000
2500
3000
...
13.00
15.88
17.88
21.88
24.75
330
403
454
556
629
13.18
19.18
19.18
19.18
19.18
335
487
487
487
487
4000
...
4000
5000
30.75
30.75
781
781
19.18
19.18
487
487
Millimeters
37.00
940
66.00
1676
A
a
Roof
line
Ba
Copper
Dual Dimensions: INCHES
B
A
Aluminum
4-Pole dimensions. For 3-Pole dimensions subtract .25/6.
8.00
203
21.00
533
Catalog Number Suffix–66 FCS37
53
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Roof Flange Kit
Ampere Ratings
6.00
152
Aluminum
Copper
Catalog
Number
...
800
...
1000
1200
800
1000
1200
1350
...
ACF-38-RF
ACF-38-RF
ACF-53-RF
ACF-53-RF
ACF-63-RF
1350
1600
2000
2500
3000
1600
2000
2500
3000
...
ACF-67-RF
ACF-78-RF
ACF-13-RF
ACF-15-RF
ACF-19-RF
4000
...
4000
5000
ACF-24-RF
ACF-24-RF
Dual Dimensions: INCHES
Millimeters
Drip
Flange
6.00
152
Roof
collar
Note: Roof flange kit will accommodate roof slope up to one inch per foot. The
roof flange kit consists of one drip flange and one roof collar and must be
ordered separately from the straight length with flange collar (66FCS37).
For “A” & “B” dimensions, refer to table above in section “straight length
with flanged collar.”
3.00
76
3.00
76
A
B
3.00
3.00
76
76
Transformer Tap (Three 1Ø Transformers)
14.00
356
42.00
1067
120.00
3048
A
N
Catalog Number Suffix–TTF
42.00
X
1067
C
C
X
6.00
152
Z
C
N
22.00
559
X
B
B
G
A
B
C
N
X
152
Z
B
N
Transformer tap
phasing for:
3Ø, 3-Pole ­
3Ø, 4-Pole - Y
6.00
X
A
Dual Dimensions: INCHES
Millimeters
A
X
6.00
152
Z
Ampere Rating
Aluminum Copper
X
Z
IN
mm
IN
mm
114
114
152
127
191
15.00
15.00
18.00
16.00
21.00
Lugs Per
Ground Lugs
Phase and Neutral
#6-300 kcmil
2/0-500 kcmil
2000
...
2500
...
3000
...
2500
...
3000
...
4.50
4.50
6.00
5.00
7.50
381
381
457
406
533
5
7
7
8
8
5
6
6
7
7
...
4000
...
4000
...
5000
4.50 114 15.00 381
6.50 165 19.00 483
6.00 152 18.00 457
10
10
13
9
9
11
54
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Adapter (Indoor Only)
Dual Dimensions: INCHES
Dual Dimensions: INCHES
Millimeters
Millimeters
I-LINE
Bolt end
I-LINE
Slot end
12.00
12.00
305
305
I-LINE II
I-LINE II
Catalog Number Suffix–12S
Catalog Number Suffix–12B
Note: Contact the factory if connecting to Series I I-LINE busway before ordering for coordination of joint and adapter details.
Phase Transition (Indoor Only)
3-Pole
Catalog # Suffix
180˚ Transition
A
B
C
C
B
A
38 PT
4-Pole
Catalog # Suffix
180˚ Transition
A
B
C
N
N
C
B
A
38 PT
180˚ Neutral Transition
A
B
C
N
N
A
B
C
38 PTN
A and C Phase Transition
A
B
C
N
C
B
A
N
38 PTAC
Catalog Number Prefix–AF2/CF2
Catalog Number Prefix–AFH2/CFH2
38.00
965
18.50
470
Dual Dimensions: INCHES
Millimeters
55
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Hanger–Horizontal Flatwise
Ampere Rating
.50 Drop rod
Aluminum
Copper
Catalog
Number
...
800
1000
...
1200
800
1000
1200
1350
...
HF-38-F
HF-43-F
HF-53-F
HF-58-F
HF-63-F
...
1350
...
1600
1600
...
2000
...
HF-67-F
HF-73-F
HF-78-F
HF-88-F
13 by customer
Dual Dimensions: INCHES
Millimeters
8.70
221
Hanger–Horizontal Flatwise
Ampere Rating
A
B
Aluminum
Copper
Catalog
Number
IN
mm
IN
mm
2000
...
2500
3000
2500
3000
...
...
HF-13-F
HF-15-F
HF-16-F
HF-19-F
16.22
18.72
19.72
22.22
412
475
501
564
14.72
17.22
18.22
20.72
374
437
463
526
...
...
4000
4000
5000
...
HF-24-F
HF-25-F
HF-26-F
27.10
28.60
29.10
688
726
739
25.60
27.10
27.60
650
688
701
CL
CL
B
A
.50 Drop rod
13 by customer
Hanger – Horizontal Edgewise
Ž
Ampere Rating
.50 Drop rod
13 by customer
A
A
Aluminum
Copper
IN
mm
Catalog
Number
800
...
1000
...
1200
800
1000
1200
1350
1600
8.36
8.36
9.86
9.86
10.86
212
212
250
250
276
HF-43-E
HF-43-E
HF-58-E
HF-58-E
HF-67-E
1350
1600
2000
...
2500
2000
...
2500
3000
...
11.86
13.86
17.24
19.74
20.74
301
339
438
501
527
HF-78-E
HF-88-E
HF-13-E
HF-15-E
HF-16-E
3000
...
4000
...
4000
5000
24.12
28.12
29.62
613
714
752
HF-19-E
HF-24-E
HF-26-E
Dual Dimensions: INCHES
Millimeters
56
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Hanger–Vertical Fixed
Channel by customer.
Hardware to secure
channel to floor and
hanger to channel
also by customer.
9.62
244
1.12
28
Housing
width
Catalog Number HF-V
1.12
28
Note: A
llow 13.25 inches (337 mm) above curb or floor to CL of joint
for proper installation of tie channel cover.
2.00
51
Dual Dimensions: INCHES
Millimeters
Finished
floor or curb
Hanger–Vertical Fixed
Hanger–Vertical Spring
Channel by customer.
Hardware to secure
channel to floor and
hanger to channel
also by customer.
9.62
244
HF-VS1
HF-VS8
1.12
28
Housing
width
1.12
28
Note: Allow 21 inches (533 mm) above cur
to CL of joint for proper installation
of tie channel cover.
2.00
Dual Dimensions: INCHES
51
Millimeters
HF-VS2
Ampere Rating
6.00
152
2.00
51
Finished
floor or curb
Hanger - Vertical Spring
Aluminum
800
1000
1200
1350
1600
...
...
2000
2500
...
3000
4000
...
Copper
800
1000
1200
...
...
1350
1600
2000
...
2500
3000
4000
5000
Catalog
Number
HF-VS1
HF-VS1
HF-VS1
HF-VS1
HF-VS1
HF-VS2
HF-VS2
HF-VS2
HF-VS2
HF-VS8
HF-VS8
HF-VS8
HF-VS8
57
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
800 A–5000 A Catalog Numbering System/Physical Data
Wall and Floor Flange
Ampere Rating
A
Aluminum
Copper
IN
mm
Catalog
Number
...
800
1000
...
1200
800
1000
1200
1350
...
8.32
8.82
9.82
10.32
10.82
211
224
249
262
275
ACF-38-WF
ACF-43-WF
ACF-53-WF
ACF-58-WF
ACF-63-WF
...
1350
...
1600
2000
1600
...
2000
...
2500
11.22
11.82
12.32
13.32
17.20
285
300
313
338
437
ACF-67-WF
ACF-73-WF
ACF-78-WF
ACF-88-WF
ACF-13-WF
...
2500
3000
...
...
4000
3000
...
...
4000
5000
...
19.70
20.70
23.20
28.08
29.58
30.08
500
526
589
713
751
764
ACF-15-WF
ACF-17-WF
ACF-19-WF
ACF-24-WF
ACF-25-WF
ACF-26-WF
10.26
261
A
Ampere Rating
Indoor
Str.
Lnth.
Aluminum Copper B
H
B
Dual Dimensions: INCHES
Millimeters
Outdoor
Str.
Lnth.
Flatwise Elbowa
Fl.
End
H
H
B
H
B
H
Edgewise Elbowa
Wall Thickness
Wall Thickness
B
4
8
12
16
20
24
4
8
12
16
20
24
...
800
1000
...
1200
800
1000
1200
1350
...
6
6
7
8
8
9
9
9
9
9
8
9
10
10
11
9
9
9
9
9
10
10
11
12
13
15
15
15
15
15
8
8
8
8
8
9
10
12
12
13
11
12
14
14
15
13
14
16
16
17
15
16
18
18
19
17
18
20
20
21
19
20
22
22
23
6
6
7
8
8
12
12
12
12
12
14
14
14
14
14
16
16
16
16
16
18
18
18
18
18
20
20
20
20
20
22
22
22
22
22
1350
...
1600
2000
...
1600
2000
...
2500
3000
9
10
11
15
17
9
8
9
9
9
12
12
13
17
20
9
9
9
9
9
14
17
17
19
23
15
21
21
21
21
8
8
8
8
8
14
15
17
22
26
16
17
19
24
28
18
19
21
26
30
20
21
23
28
32
22
23
25
30
34
24
25
27
32
36
9
10
11
15
17
12
12
12
12
12
14
14
14
14
14
16
16
16
16
16
18
18
18
18
18
20
20
20
20
20
22
22
22
22
22
2500
3000
...
...
4000
...
...
4000
5000
...
18
21
26
27
28
9
9
9
9
9
21
23
28
30
30
9
9
9
9
9
23
26
32
32
32
21
21
21
21
21
8
8
8
8
8
27
31
37
40
40
29
33
39
42
42
31
35
41
44
44
33
37
43
46
46
35
39
45
48
48
37
41
47
50
50
18
21
26
27
28
12
12
12
12
12
14
14
14
14
14
16
16
16
16
16
18
18
18
18
18
20
20
20
20
20
22
22
22
22
22
Wall thickness is in inches. To convert to millimeters, multiply the thickness in inches by 25.4.
a
End Closure (Indoor Only)
Ampere Rating
7.06
179
1.00
A
25
A
Aluminum
Copper
IN
mm
Catalog
Number
...
800
1000
...
1200
800
1000
1200
1350
...
4.34
4.84
5.84
6.34
6.84
110
123
148
161
174
ACF-38-EC
ACF-43-EC
ACF-53-EC
ACF-58-EC
ACF-63-EC
...
1350
...
1600
2000
1600
...
2000
...
2500
7.24
7.84
8.34
9.34
13.22
184
199
212
237
336
ACF-67-EC
ACF-73-EC
ACF-78-EC
ACF-88-EC
ACF-13-EC
...
2500
3000
...
...
4000
3000
...
...
4000
5000
...
15.72
16.72
19.22
24.10
25.60
26.10
399
425
488
612
650
663
ACF-15-EC
ACF-17-EC
ACF-19-EC
ACF-24-EC
ACF-25-EC
ACF-26-EC
Dual Dimensions: INCHES
Millimeters
58
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
Plug-In Catalog Numbering System
Catalog numbers are composed of two basic parts—the PREFIX, plus the SUFFIX. The PREFIX contains the general descriptive
details of the plug-in unit, and outline on pages 60–71. The SUFFIX defines the exact device type.
Number of Poles:
3 = 3Ø3W; 4 = 3Ø4W (Fusible units only)
Voltage: 2 = 240 Volts; 4 = 480 Volts, 6 = 600 Volts
Amperage Rating:
(e.g., 225 = 225 A)
Ground: (Standard on all units)
Type of Unit:
(Refer to “Type of Unit” below.)
Neutral: (Circuit Breaker Units Only)
Type of Plug-On Connection:
P = Low Ampere Plug-In Connection
PB = High Ampere Plug-In Connection
PT = High Ampere Bolt-On Connection
H = Horizontal Mounting
V = Vertical Mounting (PT Devices Only)
p
p
p
P
K
A
–
PREFIX
p
p
p
p
p
p
3
6
225
G
N
H
SUFFIX
Type of Unit
• Q–Fusible Unit; 1600 A Maximum
• LC–LC Frame Circuit Breaker Unit; 600 A Maximum
• S–Fusible Vertical Riser Unit; 200 A Only
• LH–LH Frame Circuit Breaker Unit; 400 A Maximum
• FA–FA Frame Circuit Breaker Unit; 100 A Maximum
• LI–FI Frame Circuit Breaker Unit; 600 A Maximum
• FC–FC Frame Circuit Breaker Unit; 100 A Maximum
• MA–MA Frame Circuit Breaker Unit; 1000 A Maximum
• FH–FH Frame Circuit Breaker Unit; 100 A Maximum
• MH–MH Frame Circuit Breaker Unit; 1000 A Maximum
• FI–FI Frame Circuit Breaker Unit; 100 A Maximum
• MX–MX Frame Circuit Breaker Unit; 800 A Maximum
• KA–KA Frame Circuit Breaker Unit; 250 A Maximum
• PA–PA Frame Circuit Breaker Unit; 1600 A Maximum
• KC–KC Frame Circuit Breaker Unit; 250 A Maximum
• PH–PH Frame Circuit Breaker Unit; 1600 A Maximum
• KH–FH Frame Circuit Breaker Unit; 250 A Maximum
• PX–PX Frame Circuit Breaker Unit; 1600 A Maximum
• KI–KI Frame Circuit Breaker Unit; 250 A Maximum
Note: Special purpose plug-in devices are not defined by this
catalog numbering system. Consult the factory for
cataloging details of these devices.
• LA–LA Frame Circuit Breaker Unit; 400 A Maximum
59
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
Compatibility
Plug-In Device Mounting
All plug-in units listed in this catalog may be used on original
I-LINE as well as I-LINE II busway. There is no need to stock two
different types of units.
Plug-in units are positioned along the busway length by notches
in the busway housing top that accept the mounting hooks of the
plug-in unit. This aligns the plug-in unit connectors with the plugin opening. After the unit is positioned on the busway it is allowed
to swing down into the plug-in opening where the connectors
make contact with the bus bars. This is accomplished in a “hookswing” sequence of motions.
Fusible
Plug-in switches that are 30, 60, 100, 200, 400 and 600 A contain
a heavy duty safety switch mechanism. Switches that are
800 A–1600 A contain a circuit breaker and fuses.
High visibility
ON-OFF indication
Bracket allows unit
to be padlocked in
off position
Hook stick operated
mechanism
Hinged door over
switch
Interlock
Circuit Breakers
Molded case circuit breaker plug-in devices are available in frame
sizes of 100 A (FA)–1600 A (PA) with standard, high-interrupting,
current-limiting and solid-state trip circuit breakers.
The operating handle gives visual tripped indication on all
devices, as well as floor operable reset on all devices.
The FA frame circuit breaker unit is a high-interrupting capacity
breaker that would fit into the same enclosure as the standard
molded case breaker pictured below. Mounting and the interlock
are identical to the fusible unit above.
The short circuit ratings for circuit breaker devices are listed on
page 61.
Transparent Shield over
Line Side Parts
Plug-in devices that are 30 A–250 A are interlocked with the
busway housing to prevent installation or removal of the unit
when the
disconnect is turned
ON. All devices
incorporate an
interlock to prevent the
door over the
disconnect from being
opened when the unit
is ON. This door
interlock can be
defeated from outside
Interlock
the unit.
Grounding
All plug-in units come with standard
grounding means. A grounding
spring cuts through the busway paint
and forms an electrical ground
continuity. An equipment ground is
established, before the phase jaws
make contact with the bus bars by
means of a grounding stab that
makes contact with two ground jaws
on the busway. A ground lug on the
Grounding Spring
inside of the plug-in unit is provided
for the purpose of attaching a ground wire.
60
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
Special Purpose Plug-In Devices
Horsepower Ratings
UL Horse Power Ratings
• Combination motor starter from NEMA Size 0–Size 2.
Fusible or circuit breaker primary disconnect.
• Lighting contactor. 30 A, 60 A, 100 A. Fusible disconnect.
• Magnetic contactor. NEMA Size 0–Size 2. Fusible or circuit
breaker primary disconnect.
240 Vac
• Ground detector and neutralizer. Used to provide means for
indicating grounds on an ungrounded 3-phase system and
to create a discharge path for static electricity. Consult the
factory for dimensional details.
480 Vac
• Capacitor banks. 2.5 kVAR–30 kVAR auxiliary devices.
Mount directly on busway prewired for use with separate
fusible or circuit breaker disconnect. Consult the factory for
dimensional details.
600 Vac
• Single-phase transformer plug-in devices from
1 kVA–10 kVA auxiliary devices. Mount directly on busway
prewired for use with separate fusible or circuit breaker
disconnect. Consult the factory for dimensional details.
Interrupting Capacity of Fusible Switch Plug-In Units
Catalog
Number
Prefix
Current
Rating
Fuse Class (Includes 240 V, 480 V, and
600 V)
K or H
J
R
PQ
30
10000
200000
200000
PQ
60
10000
200000
200000
PQ
100
10000
200000
200000
PQ & PS
200
10000
200000
200000
PBQ
400
10000
100000
100000
PBQA
400
...
100000
100000
PBQ
600
10000
100000
100000
Fusible Switch
Standard
30
60
100
200
400
600
30
60
100
200
400
600
30
60
100
200
400
600
Maximum
3
7.5
15
25
...
...
5
15
25
50
...
...
7.5
15
30
60
125
250
7.5
15
30
60
...
...
15
30
30
125
...
...
20
50
60
150
350
500
Type PTMA Circuit Breaker
High Ampere Bolt-on Connection
Type PBLA Circuit Breaker
High Ampere Plug-In Connection
Type PQ Fusible Switch
Low Ampere Plug-In Connection
Motor–3-Phase Horsepower Ratings
Plug-In Unit
Ampere Rating
Interrupting Capacity of Circuit Breaker Plug-In Units
Catalog
Trip Range Interrupting Rating – RMS Symmetrical Amperes
Number Prefix (Amperes)
240 Vac
480 Vac
600 Vac
With Molded Case Circuit Breakers—Standard Interrupting Capacity
PFA
PKA
PBLA
PTMA
PTPA
15-100
125-250
250-400
500-1000
1200-1600
10000
42000
42000
42000
65000
18000
25000
30000
30000
50000
14000
22000
22000
22000
42000
With Molded Case Circuit Breakers— High Interrupting Capacity
and Solid State Trip
PFH
15-100
PKH
125-250
PBLH
250-400
PTME, PTMH 500-1000
PTPE, PTPH 1200-1600
65000
65000
65000
65000
125000
25000
35000
35000
65000
100000
18000
25000
25000
25000
65000
With Molded Case Circuit Breaker—Extra High Interrupting Capacity
PFC
PKC
PBLC
15-100
125-250
300-600
100000
100000
100000
65000
65000
65000
...
...
35000
With Molded Case I-LIMITER® Current Limiting Circuit Breakers
PFI
PKI
PBLI
15-100
125-250
300-600
100000
100000
200000
100000
100000
200000
...
...
100000
65000
65000
100000
35000
25000
65000
With Electronic Trip Circuit Breakers
PBLX
PTMX
PTPX
100-600
450-800
600-2500
100000
65000
125000
61
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
Vertical Mounting
Required Clearances for Plug-In Unit Mounting
(Check These Dimensions Carefully Before Installing
Busway Lengths)
Fusible Units
Fusible switch plug-in units (30 A–100 A) mount on either side
of the vertical busway and comply with NEC Article
380-6 and CEC Article 14-502 concerning gravity tending to
close a switch blade. With unit mounted on one side of the
busway, the operating handle is on top and when mounted
on the opposite side; the handle is on the bottom. The 200 A
fusible unit (“PS”) mounts only on the front of the busway.
(“TOP” sticker on the busway is on the right). The operating
handle is on the right side of the mounted unit.
Housing
width
A
H
Top
A
B
CL
C
The 400 A–1600 A fusible units mount only on the front of the
busway. The handle is on the cover.
N
2.00
IMPORTANT: Orientation of the busway is essential for proper
mounting of plug-in units. The busway must be
positioned so that the top marking is to the right
and the neutral position is to the left.
F
51
Min.
NOTE: For required working clearances, consult the National Electrical Code/Canadian Electrical Code.
Fusible Switch
A
F
H
Cat. No. Prefix
Ampere
Rating
IN
mm
IN
mm
IN
mm
PQ
30
60
100
200
15.22
15.22
15.22
27.50
387
387
387
699
7.98
7.98
11.98
15.00
203
203
304
381
8.00
8.00
8.00
15.00
203
203
203
381
PS
200
27.50 699 9.00 229 12.00 305
PBQ
400
600
60.00 1524 7.25 184 18.00 457
60.00 1524 7.25 184 18.00 457
PTQ
800
1000
1200
1600
53.90
53.90
57.00
57.00
Circuit Breaker
Cat. No. Prefix
1369
1369
1448
1448
8.75
8.75
10.25
10.25
A
Ampere
Rating
IN
222
222
260
260
9.50
9.50
13.75
13.75
F
mm
IN
241
241
349
349
IN
mm
PFA, PFH
15-100 20.87 530 2.12 54 10.00 254
PFC, PFI
15-100 25.63 651 2.38 60 11.00 279
PKA, PKH
125-250 25.63 651 2.38 60 11.00 279
PKC, PKI
125-250 25.63 651 2.38 60 11.00 279
PBLA, PBLH
250-400 35.69 906 5.62 142 15.00 381
PBLX, PBLC, PBLI
PTMX, PTME, PTMA, PTMH
PTPX, PTPE, PTPA, PTPH
Circuit breaker plug-in units may be installed on both sides of a
riser. The restriction is that when the handle of the plug-in unit is
operated vertically rather than rotationally or horizontally, the up
position of the handle shall be the ON position.
Fusible Switch Lighting Contactor
Cat. No.
Prefix
Contactor and
Switch Rating
PSL
30 Aj
30a – 60 – 100 A
A
IN
F
mm
29.58 751
33.42 849
IN
H
mm
3.38
9.38
IN
mm
86 10.00 254
238 12.00 305
a 30 A unit with mechanically held contactor.
j 30 A unit with electrically held contactor.
Fusible Switch Starter and Contactor
Cat. No.
Prefix
H
mm
Circuit Breaker Units
PSS, PSC
Starter or
Switch
Contactor Size Rating
0–1
2
2
A
IN
PBS, PBC
Starter or
Switch
Contactor Size Rating
0, 1, 2
mm
30-60 A 27.40 696
60 A 29.58 751
100 A 33.42 849
Circuit Breaker Starter and Contactor
Cat. No.
Prefix
F
IN
IN
mm
2.13
3.38
9.38
A
H
IN
54 10.00 254
86 10.00 254
238 12.00 305
F
mm
15-90 A 27.86 708
IN
3.75
H
mm
IN
mm
95 10.00 254
300-600 35.00 889 8.00 203 20.00 508
500-1000 35.20 894 6.25 159 7.75 197
1000-1600 57.00 1448 10.25 260 13.75 349
62
© 1997–2002 Schneider Electric All Rights Reserved
mm
08/02
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
Fusible Switch Plug-In Units—30 A–100 A (Type “PQ”)
5.42
4.63
138
118
Top
Required mounting clearance
1.05
Dual Dimensions: INCHES
27
1.63
8.85
Millimeters
41
225
8.00
203
ON
G
A
B
C
N
OFF
A
B
Front
Fusible Switch
Weight
Cat. No.
Prefix
Ampere
Rating
Lb
PQ
30
60
100
15.0
15.0
17.0
Lugs Per Phase
Lugs Per Neutral
Ground Lugs
A
B
Kg
Qty.
Size
Qty.
Size
Qty.
Size
IN
mm
IN
mm
33.0
33.0
37.5
1
1
1
#12 – #2
#12 – #2
#12 – #1/0
1
1
1
#12 – #1/0
#12 – #1/0
#12 – #1/0
1
1
1
#10 – #2
#10 – #2
#10 – #2
14.95
14.95
18.97
379
379
480
7.98
7.98
11.98
203
203
304
Fusible Switch Plug-In Unit–200 A (Type “PQ”)
Weight
(Approx.)
Fusible Switch
Cat. No. Ampere
Prefix
Rating
PQq
200
Lugs Per Phase and
Neutral
Ground Lugs
Lb
Kg
Qty.
Size
Qty.
Size
71
32
1
#6-300 kcmil
1
#10-2/0
9.72
247
q 200 A “PQ” units are for use primarily on horizontally mounted busway.
Refer to “PS” units for use primarily on vertically mounted busway.
CL
11.44
291
Dual Dimensions: INCHES
Millimeters
.56 Dia.
14
Required mounting clearance
14.40
366
16.17
1.13
411
29
15.00
381
3.48
88
ON
G
A
B
C
N
OFF
22.48
571
13.12
333
63
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
Fusible Switch Plug–In Unit 200 A (Type “PS”)
NCBAG
Weight
(Approx.)
Fusible Switch
Cat. No. Ampere
Prefix
Rating
Top
PSq
9.09
11.44
231
291
CL
18.00
457
16.17
Ground Lugs
Lb
Kg
Qty.
Size
Qty.
Size
71
32
1
#6-300 kcmil
1
#10-2/0
q 200 A “PS” units for use on one side of vertically mounted busway only. To
determine proper mounting side for this unit, position busway “TOP” mark­
ing to the right (same side as unit operating handle) and the neutral bus bar
to the left as shown in top view of drawing. Refer to “PQ” units for use on
horizontally mounted busway.
Required mounting clearance
1.13
411
200
Lugs Per Phase and
Neutral
Dual Dimensions: INCHES
Millimeters
29
1.11
14.22
28
361
3.71
94
ON
22.48
OFF
571
Fusible Switch Plug–In Unit 400 A (Type “PBQ”)
Weight
(Approx.)
Fusible Switch
Cat. No. Ampere
Prefix
Rating
PBQf
400
Lugs Per Phase
and Neutral
Ground Lugs
4.34
Lb
Kg
Qty.
Size
Qty.
Size
195
89
2
#4-600 kcmil
1
#3/0-600 kcmil
110
f 400 A “PBQ” unit plugs into one opening, but requires space equal to two
plug-in openings.
Note: For vertical riser applications for I-LINE II busway, order auxiliary kit
catalog number PBQ-4060-RMK. This kit is not suitable for installation
on I-LINE busway from 225 A–600 A in a vertical riser mounting.
Required mounting clearance
4.00
102
CL
13.75
349
Dual Dimensions: INCHES
Millimeters
1.27
42.00
32
1067
18.00
457
1.40
36
ON
8.93
227
Top
G
A
B
C
N
20.95
532
6.14
156
OFF
64
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
Fusible Switch Plug-In Unit— 600 A (Type “PBQ”)
Fusible Switch
Weight
(Approx.)
Lugs Per Phase and
Neutral
110
Ampere
Rating
Lb
Kg
Qty.
Size
Qty.
Size
PBQf
600
195
89
2
#4-600 kcmil
1
#3/0-600
kcmil
f
4.34
Ground Lugs
Cat. No.
Prefix
600 A “PBQ” unit plugs into one opening but requires space equal to two
plug-in openings.
CL
13.75
349
Note: For vertical riser applications for I-LINE II busway, order auxiliary kit catalog
number PBQ-4060-RMK. This kit is not suitable for installation on
I-LINE busway from 225 A–600 A in a vertical riser mounting.
Required mounting clearance
4.00
102
Dual Dimensions: INCHES
Millimeters
1.27
42.00
32
1.40
1067
18.00
457
36
ON
8.93
227
Top
G
A
B
C
N
20.95
532
6.14
156
OFF
Fusible Switch Plug-In Unit— 400 A (Type “PBQA”)
Fusible Switch
a
Weight
(Approx.)
Lugs Per Phase
and Neutral
Ground
Lugs
Cat. No.
Prefix
Ampere
Rating
Lb
Kg
Qty.
Size
Qty.
Size
PBQAa
400
118
53.5
1
500 kcmil
1
1/0
Contains Class R fuse kits installed at factory.
Note: Lugs are compression type.
13.07
Required mounting clearance
332
Dual Dimensions: INCHES
Millimeters
4.00
22.21
564
1.20
102
1.27
32
17.37
453
30
5.06
18.00
129
457
ON
OFF
G
A
B
C
N
18.99
482
8.05
204
65
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
Fusible Switch Bolt-On Units — 800 A–1600 A (Type “PTQ”)
Bolt-on units may be used only on plug-in busway
(800 A–4000 A—except 800 A copper I-LINE II) with the same
number of poles. (e.g., Do not use 3-pole unit on 3Ø4W
busway, or 3Ø4W unit on 3-pole busway.)
Required mounting clearance
I
Top
CL
C
Dual Dimensions: INCHES
Millimeters
D
A
Drop rods
by customer
H
G
E
Top
G
A
B
C
N
CL
Front
OFF
B
ON
F
4.00
1.62
Fusible Switch
A
4.00
102
41
B
C
D
102
E
F
G
H
I
Cat. No.
Prefix
Ampere
Rating
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
PTQ
800
1000
1200
1600
49.75
49.75
56.25
56.25
1264
1264
1429
1429
18.62
18.62
24.25
24.25
473
473
616
616
12.40
12.40
16.00
16.00
315
315
406
406
16.50
16.50
20.10
20.10
416
416
510
510
4.75
4.75
9.00
9.00
121
121
229
229
7.75
7.75
9.25
9.25
197
197
235
235
6.03
6.03
10.28
10.28
153
153
261
261
9.50
9.50
13.75
13.75
241
241
349
349
5.75
5.75
9.00
9.00
146
146
229
229
Fusible Switch
Cat.
Ampere
No.
Rating
Prefix
PTQj
800
1000
1200
1600
Weight
Lugs Per Phase
and Neutral
Ground Lugs
Lb
Kg
Qty.
Size
Qty.
Size
230.00
230.00
350.00
350.00
103
103
159
159
3
3
6
6
2/0 – 500 kcmil
2
2
2
3
2/0 – 500 kcmil
j “PTQ” units plug into one opening, but require space equal to three plug-in openings
(See dimension A).
Note: This unit requires a special hanger that is mounting orientation specific. Add “H”
on the end of the catalog number for units that will be mounted horizontally, and “V”
for units that will be mounted vertically. These mounting frames are NOT interchangeable.
66
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
Circuit Breaker Plug-In Units—15 A–250 A
Circuit Breaker
A
Cat. No. Prefix
Trip Range
(Amperes)
PFA, PFH
PKA t, PKC, PKH t
PFC
15-100 A 13.00
125-250 A 16.38
15-100 A 16.38
Circuit Breaker
Cat. No.
Prefix
Trip
Range
(Amperes)
IN
C
D
E
F
H
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
330
416
416
8.25
8.50
8.50
210
216
216
6.62
8.00
8.00
168
203
203
8.62
9.12
9.12
219
232
232
1.12
1.00
1.00
28
25
25
1.12
1.38
1.38
28
35
35
2.00
2.00
2.00
51
51
51
10.00
11.00
11.00
254
279
279
Ground Lugs
Kg
Qty.
Size
Qty.
Size
13
13
18
1
1
1
1
1
#14 – 4
#14 – 1/0
#4 – 300 kcmil
#14 – 10
#14 – 3
1
1
1
1
1
#10 – #2
#10 – #2
#6 – 2/0
#10 – 2
#10 – 2
Top
PFA, PFH
15-30 A 28.0
PFA, PFH 35-100 A 28.0
PKA, PKH 125-250 A 39.0
PFC
15-30 A 53.0
PFC
35-100 A 53.0
G
mm
Lugs Per Phase
and Neutral
Weight
Lb
B
C
CL
3.25
1.38
Dual Dimensions: INCHES
83
35
Millimeters
Required mounting clearance
A
D
H
G
E
ON
Top
G
A
B
C
N
CL
G
A
B
C
N
Front
B
OFF
F
* Reverse Feeding of Circuit Breaker Plug-In Units
Circuit breaker plug-in units are capable of reverse feeding a run of plug-in busway. To convert standard plug-in units for this application in the field, order a
label kit (Cat # RFLK). For further assistance, contact factory for ordering information.
I-LIMITER® Current-Limiting Circuit Breaker Plug-In Units—15 A–250 A
Circuit Breaker
Cat. No. Prefix
PFI
PKI
Circuit Breaker
Cat. No.
Prefix
PFI
PFI
PKI
Trip
Range
(Amperes)
A
Trip Range
(Amperes)
IN
15-100 A 16.38
125-250 A 16.38
Weight
(Approx.)
Lb
15-30 A 32.0
35-100 A 32.0
125-250 A 53.0
B
C
D
E
F
G
H
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
416
416
8.50
8.50
216
216
8.00
8.00
203
203
9.12
9.12
232
232
1.00
1.00
25
25
1.38
1.38
35
35
2.00
2.00
51
51
11.00
11.00
279
279
Lugs Per Phase
and Neutral
Ground Lugs
Kg
Qty.
Size
Qty.
Size
15
15
24
1
1
1
#14 – 4
#14 – 1/0
#6 – 300 kcmil
1
1
1
#6 – 1/0
#6 – 1/0
#10 – #2
Top
C
CL
3.25
1.38
Dual Dimensions: INCHES
83
35
Millimeters
Required mounting clearance
A
D
H
G
E
Top
G
A
B
C
N
CL
ON
Front
B
OFF
G
A
B
C
N
F
67
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
I-LIMITER® Current-Limiting Circuit Breaker Plug-In Units— 300 A–600 A
4.34
110
CL
Top
0.47 Dia. hole
9.77
12
(2 Holes)
Dual Dimensions: INCHES
248
Millimeters
Required mounting clearance
Drop rod by
customer
37.87
14.86
962
377
4.00
102
20.00
508
5.38
137
1.25
G
A
B
C
N
CL
32
18.20
Front
OFF
462
ON
7.07
180
Circuit Breaker
Weight (Approx.)
Lugs Per Phase
Ground Lugs
Lugs On Neutral
Cat. No. Prefix
Triple Range
(Amperes)
Lb
Kg
Qty.
Size
Qty.
Size
Qty.
Size
PBLIq
300-600
127.0
58
2
#4 – 300 kcmil
1
#6 – 300 kcmil
3
3/0 – 500 kcmil
q
“PBLI”units plug into one opening, but require space equal to two plug-in openings.
Circuit Breaker Plug-In Units—250 A– 400 A
4.50
114
CL
7.13
181
Dual Dimensions: INCHES
Required mounting clearance
Millimeters
17.00
27.31
1.10
432
694
28
15.00
381
5.75
ON
146
Top
G
A
B
C
N
Front
OFF
15.25
387
3.62
92
Circuit Breaker
Weight (Approx.) Lugs Per Phase and Neutral
Ground Lugs
Cat. No.
Prefix
Triple Range
(Amperes)
Lb
Kg
Qty.
Size
Qty.
Size
PBLA, PBLH
250-400
78
35
1
#1 – 600 kcmil
1
#6 – 300 kcmil
“PBLA” and “PBLH” units plug into one opening, but require space equal to two plug-in openings.
68
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
Circuit Breaker Plug-In Units—300 A– 600 A
4.34
110
CL
Top
Dual Dimensions: INCHES
0.47 Dia. hole
Millimeters
Required mounting clearance
9.77
12
(2 Holes)
248
Drop rod by
customer
14.86
37.87
377
962
4.00
102
20.00
508
5.38
137
1.25
G
A
B
C
N
CL
32
18.20
Front
OFF
462
ON
7.07
180
Circuit Breaker
Weight (Approx.)
Lugs Per Phase
Ground Lugs
Lugs On Neutral
Cat. No. Prefix
Triple Range
(Amperes)
Lb
Kg
Qty.
Size
Qty.
Size
Qty.
Size
PBLCq
300-600
127.0
58
2
4/0 – 500 kcmil
1
#6 – 300 kcmil
2
2/0 – 500 kcmil
q
“PBLC” units plug into one opening but require space equal to two plug-in openings.
Circuit Breaker Bolt-On Units—500 A–1600 A
Note: Bolt-on units may be used only on plug-in busway
(800 A–4000 A—except 800 A copper I-LINE II) with the
same number of poles. (E.g., Do not use 3-pole unit on
3Ø4W busway, or 3Ø4W unit on 3-pole busway.)
5.75
146
Top
CL
C
Required mounting clearance
Dual Dimensions: INCHES
Millimeters
D
A
Drop rods
by customer
H
G
E
G
A
B
C
N
CL
Top
Front
OFF
B
ON
F
4.00
1.62
Circuit Breaker
A
Trip Range
(Amperes)
Cat. No. Prefix
PTMAj, PTMH
PTMX
PTPAj, PTPH, PTPX
IN
500-1000 31.62
500-800 31.62
1000-1600 56.75
Circuit Breaker
4.00
102
41
B
C
102
D
E
F
H
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
803
803
1441
14.12
14.12
24.25
359
359
656
12.50
12.50
16.00
318
318
406
16.60
16.60
20.10
422
422
510
2.75
2.75
9.00
70
70
229
5.25
5.25
9.25
133
133
235
4.25
4.25
10.50
390
390
648
7.75
7.75
13.75
197
197
349
Weight (Approx.) Lugs Per Phase and Neutral
Ground Lugs
Cat. No.
Prefix
Triple Range
(Amperes)
Lb
Kg
Qty.
Size
Qty.
Size
PTMAj, PTMH
PTMX
PTPAj, PTPH, PTPX
500-1000
500-800
1000-1600
160.0
160.0
350.0
73
73
159
3
3
6
3/0 – 500 kcmil
3/0 – 500 kcmil
2/0 – 500 kcmil
2
2
3
2/0 – 500 kcmil
2/0 – 500 kcmil
2/0 – 500 kcmil
j
G
mm
Note: This unit requires a special hanger that is
mounting orientation specific. Add “H” on
the end of the catalog number for units
that will be mounted horizontally, and “V”
for units which will be mounted vertically.
These mounting frames are NOT
interchangeable.
“PTMA”, “PTMH”, “PTMX”, “PTPA”, “PTPH”, and “PTPX” units plug into one opening but require space equal
to two or three plug-in openings (See Dimension A.)
69
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
Combination Fusible Switch and Starter—Lighting Contactor—Contactor
Fusible Switch and Starter/Lighting Contactor/Contactor
164
14.87
Fusible Switch
Rating
0-1
...
30-60 A
2
...
60 A
2
...
100 A
...
30 A
30 A
...
60 A
60 A
...
100 A
100 A
PSL
39
122
Lighting
Contactor Size
PSS, PSC
1.54
4.81
Top View
Starter or
Contactor Size
Cat. No. Prefix
4.64
118
6.47
7.98
378
203
Note: All device ratings fit in the same enclosure dimensions as shown above.
G
A
B
C
N
14.95
3.93
100
380
7.74
197
Front View
Dual Dimensions: INCHES
Side View
Millimeters
Ground Detector and Neutralizer
5.42
4.63
138
118
Top
Required mounting clearance
1.05
1.63
8.85
27
41
225
8.00
203
ON
G
A
B
C
N
OFF
Switch jaws
240 Vac Tap
480 Vac Tap
600 Vac
Resistors
14.95
380
7.98
Indicating 240 V
neon lamp
203
Enclosure
Ground
Front
Dual Dimensions: INCHES
Millimeters
Voltage Rating
Catalog Number
240 Vac
600 Vac
Wiring Diagram
Note: The ground detector and neutralizer plug-in unit consists of a disconnect,
a high resistance connection from each phase-to-ground, and neon indi­
cating lights wired in parallel with the resistors. The resistors provide a
discharge path for high transient voltages that may be impressed
temporarily on the busway system.
Weight
Lb
Kg
PGD-3200G
16.0
35
PGD-3600G
16.0
35
The neon indicating lights provide visual indication of grounds in a 3ø3W
ungrounded system. Operation of the lights is such that under normal
conditions all three lights glow dimly under half voltage. If one phase goes
to ground, the indicating light associated with that phase goes out while
the other two assume full brilliance under full voltage conditions.
70
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Catalog Numbering System/Plug-In Units ("Bus Plugs")
Combination Circuit Breaker And Starter — Contactor
CL Top
H
G
E
D
A
1.25
32
ON
Top
G
A
B
C
CL
Millimeters
83
35
Drop rod
by customer
Dual Dimensions: INCHES
3.25
1.38
Required mounting clearance
C
Front
G
A
B
C
B
OFF
F
Circuit Breaker and Contactor
Cat. No.
Prefix
Starter or
Breaker
Contactor Size Rating
PBS, PBC
0, 1, 2
A
IN
15-90 A 20.42
B
C
D
E
F
G
H
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
519
9.76
248
6.19
157
8.50
216
1.00
25
2.75
70
1.63
41
10.00
254
71
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
Suggested Busway Specifications
1.0 General
Short Circuit Rating and Tests
1.1 Quality Assurance
All busway products shall be manufactured in a facility that is
Quality Systems Registered by Underwriters Laboratories
Inc. (UL®) to ISO 9001: 2000.
1.2 Regulatory Requirements
a. The short circuit rating of the busway shall be (consulting
engineer’s calculated required rating __ )RMS symmetrical
amperes, which is the ultimate anticipated short circuit
current available at the source.
b. The short circuit rating of the busway shall be determined
according to UL Standards 857. This rating must be based
upon actual tests at the rated short circuit current.
2.3 Basic Construction
Underwriters Laboratories Listing
Housing
a. All straight lengths, fittings, and plug-in units shall be UL
Listed.
b. This listing shall include mounting of the busway in any
position (e.g., horizontal flatwise, horizontal edgewise, and
vertical) without derating.
1.3 Delivery, Storage, and Handling
Refer to NEMA Type Publication BU1.1, which is a guide for
proper installation, operation, and maintenance of busway
products.
1.4 Maintenance
Refer to NEMA Type Publication BU1.1, which is a guide for
proper installation, operation, and maintenance of busway
products.
2.0 Products
a. The busway housing shall be constructed of code gauge
steel and aluminum to reduce hysteresis and eddy current
losses and shall be provided with a suitable protective finish
of ANSI 49 gray epoxy paint.
b. The busway housing shall be totally enclosed nonventilated for protection against mechanical damage and
dust accumulation.
c. The totally enclosed housing shall be manufactured by the
busway manufacturer. Modifications of busway to make it
totally enclosed by other than the busway manufacturer
voids the manufacturer’s warranty. Busway so modified is
unacceptable without the written consent of the
manufacturer.
Joints
a. The busway joint shall be of the one-bolt type which utilizes
a high strength steel bolt(s) and conical washers to
maintain proper pressure over a large contact surface area.
b. The bolt shall be torque-indicating and at ground potential.
2.1 Manufacturers
All busway shall be I-LINE/I-LINE II busway manufactured by
Square D.
2.2 Manufactured Units
General
a. Furnish and install a complete low impedance
prefabricated busway distribution system as shown on the
plans.
b. Busway shall be __ Volts, __ phase __ wire with 50%
capacity integral ground bus.
c. The ampere ratings, approximate footage, fitting, plug-in
units, etc., are shown on the plan. The electrical contractor
shall be responsible for routing the busway to coordinate
with the other trades. Final field measurements shall be
made by the contractor prior to release of the busway for
fabrication by the manufacturer.
c. The bolt shall be two-headed design to indicate when
proper torque has been applied and require only a standard
long handle wrench to be properly activated.
d. Access shall be required to only one side of the busway for
tightening joint bolts.
e. On busway 800 A and above, it shall be possible to remove
any joint connection assembly to allow electrical isolation or
physical removal of a busway length without disturbing
adjacent busway lengths.
Bus Bars
a. Bus bars shall be plated.
b. Each bus bar shall be insulated with Class B rated
(130 °C (266 °F) vendor certified) polyester film or epoxy
powder coated materials.
c. The temperature rise at any point in the busway shall not
exceed 55 °C (131 °F) rise above ambient temperature
when operating at rated load current.
d. Both feeder and plug-in busway (800 A and above) shall be
of sandwich construction, meaning no air gap shall exist
between bus bars except at plug-in openings.
72
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
Suggested Busway Specifications
Plug-In Openings
2.7 Plug-In Unit Safety Devices
a. On plug-in busway, there shall be five deadfront, hinged
cover-type plug-in openings on each side of 10-foot
(305 cm) lengths.
a. Each plug-in unit rated 100 A or below shall be
mechanically interlocked with the busway housing to
prevent installation or removal of plug-in units while the
switch is in the ON position, and be equipped with an
operating handle which always remains in control of the
switching mechanism.
b. All openings shall be usable simultaneously.
c. Busway shall be installed so that plugs are side mounted to
permit practical use of all ten plug-in openings.
d. Each phase position of a plug-in opening shall be
individually insulated.
e. It shall be possible to inspect the plug-in opening and bus
bars prior to the installation of the plug-in unit.
2.4 Support of Busway
a. Hanger spacing shall be noted on layout drawings and shall
not exceed manufacturer’s recommendations.
b. Indoor feeder and plug-in busway shall be approved for
hanger spacing of up to 10 ft (305 cm) for horizontally
mounted runs and 16 ft (488 cm) for vertically mounted
runs. Outdoor feeder busway shall be approved for
spacing of up to 5 ft (152 cm) for horizontally or vertically
mounted runs.
b. Plug-in enclosures shall make positive ground connection
with the ground bus before the jaws make contact with the
phase bars.
— The ground method shall be such that it cannot be
defeated by future painting of the busway housing.
c. The plug-in units shall be equipped with internal barriers to
prevent accidental contact of fish tape and conductors with
live parts on the line side of the protective device during
time of wire pulling.
d. Covers of all plug-in units must have interlocks to prevent
the cover from being opened when the switch is in the ON
position.
3.0 Execution
3.1 Installation
2.5 Voltage Drop
a. The voltage drop (input voltage minus output voltage)
specified shall be based on the busway operating at full
rated current and at stabilized operating temperature in
30 °C (86 °F) ambient.
b. The three-phase, line-to-line voltage drop shall not exceed
3.1 Volts per hundred feet at 40% power factor
concentrated load which may exist during motor starting.
c. The line-to-line voltage drop shall not exceed 4.0 Volts per
hundred feet at the load power factor which produces
maximum voltage drop in the busway.
a. Install busway and accessories in accordance with
manufacturer’s instructions. Additional instructions are
detailed in NEMA Type publication BU1.1, which is
provided with the equipment by the electrical manufacturer.
b. Install busway length with expansion fitting at each location
where busway run crosses building expansion.
c. Provide curb around interior floor penetrations.
d. Install busway with integral weather seal located where
busway penetrates [exterior wall] [roof]. Provide [wall] [roof]
flange and seal around opening to maintain weather tight
installation.
2.6 Plug-In Units
a. Plug-in units shall be [circuit breaker type] [fusible switch
type with visible blade quick-make and quick-break
mechanism].
b. Plug-in units which cannot be operated directly from the
floor shall be equipped with suitable means for hookstick
operation.
c. The interrupting rating of circuit breaker plug-in units shall
be __ RMS symmetrical amperes.
73
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
100 A Plug-In Busway
100 A Busway Mounted in the Edgewise Position
General
Ground Bus (Optional)
We offer a full line of 100 A plug-in busway especially designed
for light commercial and industrial jobs. This busway carries up
to a 14,000 A short circuit rating and is available for “quick ship”
with either copper or aluminum bus bars.
Internal ground bus equal to 50% phase capacity.
Steel housing
Aluminum or copper bus
General-duty 100 A busway with ground bus system is also
available. A unique grounding jaw ensures positive contact
between the busway and plug-in unit.
Compared to cable and conduit, 100 A busway saves costly
installation time. What’s more, it’s reusable, too, if the distribution
system is changed in the future. So, consider these features. The
next time you have a job that’s too small for busway, choose
100 A busway.
Insulator and bus
bar support
Type
Totally enclosed plug-in busway.
Ratings
Bus Bar Support
100 A, continuous full load current.
Molded bus bar insulators.
UL Listing
Housing
File Number E22182.
Twenty gauge steel, bonderized and finished with gray epoxy
paint. Twistout steel plates cover plug-in access openings along
both sides of the housing on 26 1/4-inch (6 mm) centers.
Systems
Rated for 3Ø4W, and for 3Ø3W, up to 600 Volt maximum.
Short Circuit Bracing
Conductors
Round, electrical grade aluminum or copper.
Bracing is provided by the molded insulating supports at each
plug-in opening.
Plating
Short Circuit Ratings: UL Three Cycle Test
(KA, RMS Symmetrical)
Electro-plated over entire length.
480 V
600 V
Copper Busway
14
14
Aluminum Busway
14
10
74
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
100 A Plug-In Busway
Joint
Hangers
High pressure spring type connectors join electrical conductors at
each joint. These connectors are mounted on molded insulators
and position the bus bars for joining.
Wrap-around type hanger for mounting plug-in busway in the
edgewise position is standard. Busway is UL Listed for 10 ft
(305 cm) hanger spacing in edgewise position.
“C” clamp hangers are available for use in either edgewise or
flatwise mounting position. UL Listing for flatwise mounting
position is with busway hung on 5 ft (152 cm) centers.
Spring connectors
Scarf-lap
joint
Voltage Drop
In using curve, the following notes are applicable:
• For balanced 3-phase, line-to-line voltage drop of 4-wire
duct, use values from curve.
• For balanced 3-phase, line-to-neutral voltage drop, multiply
values from curve by .577.
• For single-phase voltage drop, multiply values from curve by
1.15.
• For other than rated currents, multiply values from curve by
Actual Current.
Rated Current
• For different lengths, multiply values from curve by
Actual Footage.
100 ft Average 3-Phase, Line-To-Line Voltage Drop
In Volts Per 100 Feet At Rated Current
With Balanced 3-Phase Load
3
Voltage Drop
Per 100 Feet
2
A LU
M ---M I NU
1
0
10
20
30
40
Load
buted
Distri
d
uted Loa
--- Distrib
C O P P ER -
50
60
70
80
90
100
3-Phase Load Power Factor in Percent
75
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
100 A Plug-In Busway
Straight Lengths
6.00
26.25
152
26.25
667
26.25
667
26.25
667
9.00
667
3.50
229
89
Top
3.50
89
9.00
26.25
229
26.25
667
26.25
667
26.25
667
6.00
667
152
Front
120.00
3048
Dual Dimensions: INCHES
CL Joint
CL Joint
Millimeters
Joint Detail
Standard Lengths–Feet
10
5
3
Standard Lengths–Meters
3.05
1.52
0.91
Number of Plug-In Openings
10
6
4
Busway Construction
Enclosure
Aluminum bus bar
Enclosure
Outlet cover
(Twistout)
Insulator
Ground bus
(Optional)
Dual Dimensions: INCHES
Millimeters
Cross Sections
1.75
Top
45
3Ø3W
3Ø4W
Top
Top
.281 Dia. hole
7
Neutral
Neutral
AØ
AØ
5.38
137
AØ
BØ
B Ø
BØ
C Ø
G*
C Ø
G*
CØ
*Optional internal ground bus equal to 50% phase capacity
Dual Dimensions: INCHES
Millimeters
Internal
ground
bus
Polarizing Plug Outlet
76
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
100 A Plug-In Busway
Elbows
CL Joint
10.00
254
10.00
10.00
254
254
Dual Dimensions: INCHES
Millimeters
TO
FR P
ON
T
CL Joint
Dual Dimensions: INCHES
CL Joint
10.00
Millimeters
254
CL Joint
Front Outside: Catalog Number Suffix–LFO
Front Inside: Catalog Number Suffix–LF
Tees
CL Joint
CL Joint
10.00
10.00
254
254
P
TO NT
O
FR
P
TO NT
O
FR
FR
ON
T
Dual Dimensions: INCHES
10.00
Millimeters
10.00
254
CL Joint
10.00
254
CL Joint
TO
FR P
ON
T
CL Joint
254
10.00
Dual Dimensions: INCHES
Millimeters
254
CL Joint
Front Outside: Catalog Number Suffix–TFO
Front Inside: Catalog Number Suffix–TFI
Hangers
.406 Dia. hole
10
Angle Iron
by customer
Dual Dimensions: INCHES
Millimeters
7.25
.75
184
19
Dual Dimensions: INCHES
Millimeters
Dual Dimensions: INCHES
Millimeters
5.44
138
1.25
1.94
32
“C” Clamp Flatwise
Catalog Number–HP1F
49
Wrap-Around Edgewise
Catalog Number–HP1E
Wall Flange End Closure
End Closure
3.76
Outer Cover
4.00
96
1.88
Wall Mounted
CL Joint
102
48
Dual Dimensions: INCHES
Millimeters
Dual Dimensions: INCHES
Millimeters
7.25
184
Catalog Number–ACP1WF
Catalog Number–ACP1EC
Catalog Number–ACP1OC
77
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
100 A Plug-In Busway
Circuit Breaker Plug-In Units
Knockout Sizes– .50 in. (13 mm), .75 in. (19 mm), 1.00 in.
(25 mm), 1.25 in. (32 mm), K.O.’s in all sides
3.25
83
Lugs – #14 – 1/0 per neutral and ground size of phase lugs
determined by circuit breaker ampere rating.
Neutral
5.00
127
Note: Circuit breakers and enclosures are ordered and shipped
separately for ease of installation and are shown
assembled above for reference purposes only.
Dual Dimensions: INCHES
Millimeters
Catalog
Number—
PIN-QO
8.19
208
Knockout Sizes– .50 in. (13 mm), .75 in. (19 mm), 1.00 in.
(25 mm), 1.25 in. (32 mm)
3.25
83
Lugs – #14 – 1/0 per neutral and ground. Size of phase lugs
determined by circuit breaker ampere rating.
5.06
129
Neutral
15.79
Dual Dimensions: INCHES
Catalog
Number—
PIN-QOR
401
Millimeters
Note: Enclosure with space for three QO Circuit Breaker poles
and provisions for three duplex receptacles. Circuit
breakers are not provided.
Knockout Sizes–End wall– .50 in. (13 mm), .75 in. (19 mm), 1.00
in. (25 mm), 1.25 in. (32 mm), 1.50 in. (38 mm), 2.00 in. (51 mm)
Top and Bottom – .50 in. (13 mm), .75 in. (19 mm), 1.00 in.
(25 mm), 1.25 in. (32 mm)
3.65
93
6.18
157
Neutral
Lugs– #14–1/0 per neutral and ground size of phase lugs
determined by circuit breaker ampere rating.
Note: Will accept 15 A–100 A FAL circuit breaker.
14.56
Dual Dimensions: INCHES
370
Millimeters
Catalog
Number–
PIN-100FA
Cable Tap Boxes – Plug-In Cable Tap Box
Floor Operated Attachment
3.66
93
Neutral
6.20
157
Dual Dimensions: INCHES
Millimeters
Catalog Numbers—
3Ø3W–PTB13; 3Ø4W–PTB14
6.06
Catalog Numbers—PI-1-QO used with PINQO and PIN QOR
PI-1-FA used with PIN 100FA
154
Plug-In Cable Tap Box
Knockout Sizes– .50 in. (13 mm), .75 in. (19 mm), 1.00 in.
(25 mm), 1.25 in. (32 mm), 1.50 in. (38 mm), 2.00 in. (51 mm)
Lugs– #14–2/0 per phase and neutral, #14 – 1/0 per ground
78
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
100 A Plug-In Busway Suggested Specifications
1.0 General
Joints
1.1 Quality Assurance
a. Electrical connection shall be made at the joints by high pressure spring type connectors.
All busway products shall be manufactured in a facility, which
is Quality Systems Registered by Underwriters Laboratories
Inc. to ISO 9001: 2000.
b. All hardware required for joining sections shall be captive.
c. Loose hardware will not be permitted.
2.3 Bus Bars
1.2 Regulatory Requirements
a. The conductors shall be fabricated from round (aluminum)
(copper) rods.
Underwriters Laboratories Listing
b. Conductors are to be electrolytically plated over their entire length. a. All straight lengths, fittings and plug-in units shall be UL
Listed.
c. Insulators shall be of the type which isolates the jaws of a
plug-in device from each other.
b. This listing shall include mounting of the 100 A plug-in
busway in any position (e.g., horizontal, edgewise and
flatwise and vertical) without derating.
d. Fault current bracing shall be 14,000 RMS amperes for copper busway or 10,000 RMS amperes for aluminum
busway.
c. Plug-in busway shall be 100 A plug-in busway
manufactured by Square D.
Plug-In Openings
2.0 Products
a. The enclosure shall include ten plug-in outlets in each 10-foot (305 cm) length.
2.1 Manufactured Products
b. All plug-in openings shall be usable simultaneously.
General
2.4 Support of Busway
a. Furnish and install a complete prefabricated plug-in
busway distribution system as shown on the plans.
Bus bars shall be firmly supported by molded insulators on alternate sides of the housing.
b. Plug-in busway shall be 100 A,______Volts, ______phase,
______wire.
2.5 Plug-In Units
c. The approximate footage, fittings, plug-in units, etc., are as
shown on the plans. The electrical contractor shall be
responsible for routing the plug-in busway to coordinate
with other trades. Final field measurements shall be made
by the contractor prior to release of the plug-in busway for
fabrication. Hanger spacing (Shall be as shown on the
plans) (Shall not exceed 10 ft (305 cm)).
All plug-in units are to be polarized to insure correct phase
orientation and shall include a means of securely fastening the
device to the plug-in busway housing with a bolted clamp.
2.2 Basic Construction
Housing
a. The 100 A plug-in busway shall be of the totally-enclosed
type for protection against mechanical damage and dust
accumulation.
b. Each plug-in outlet shall be accessible by the removal of a
steel twistout cover and shall accept a closing cap when not
in use.
c. The entire system shall be constructed using
manufacturer's standard sections. As many sections as
possible shall be 10-foot (305 cm) lengths.
d. Fittings shall be made in such a way that no increase of
housing size is required at the connection between
adjoining sections.
79
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
POWER-ZONE™ Metal-Enclosed Busway
General
POWER-ZONE™ metal-enclosed, non-segregated phase
medium and low voltage bus systems are custom-designed and
manufactured. Standard sizes and ratings and a complete line of
components allow each system to be tailored to suit the
requirements of each application, while at the same time provide
the reliability that our name has stood for around the world for so
many years.
Standard bus systems are available in four basic voltage classes:
600 V, 5 kV, 15 kV and 38 kV with a full range of continuous selfcooled current ratings and momentary current ratings. Other
voltage classes are available upon request. Components such as
equipment terminations, horizontal and vertical elbows, tee-taps,
phase transpositions, expansion joints, earthquake and vibration
joints, misalignment joints, wall and floor penetration assemblies,
fire and smoke barriers, bus supports, etc., are also available for
all sizes and ratings.
POWER-ZONE bus design and construction is in strict
accordance with ANSI Standard C37.23. It can be supplied with
full, round edge 98% IACS copper or 57% IACS aluminum bars.
Copper contact surfaces are silver-plated. Aluminum contact
surfaces are tin-plated. All aluminum electrical connections are
fitted with conical washers to maintain a constant contact
pressure.
On outdoor applications, bottom covers are equipped with
screened breathers to eliminate the accumulation of moisture
within the housing. In addition, manually or themostatically
controlled electric strip heaters are provided to aid condensation
control.
To complete the system, a line of steel structural supports is also
available for both indoor and outdoor applications.
Housing Construction
Totally enclosed indoor or outdoor.
Housing Material
Aluminum standard; Galvanized or stainless steel optional.
Conductors
Silver-plated copper or tin-plated aluminum.
Conductor Supports
Glass-reinforced polyester or porcelain.
Insulation
Fluidized bed epoxy (130°C) (266 °F).
Standard hardware for conductor joints is plated steel for bare
connections not exposed to weather, or insulated connections
where the bus rating does not exceed 5000 A. Hardware is
stainless steel for bare connections exposed to weather and all
connections where the bus ratings exceeds 5000 A.
With the exception of 600 V class, which is normally uninsulated,
the bus conductors are insulated with a flame-retardant,
non-hygroscopic, high dielectric strength fluidized bed epoxy
insulation rated 130°C (266 °F). The 5000 V and 15000 V
busway joints are insulated with removable insulating boots,
while the 38,000 V busway joints are taped.
The 5 kV and the 15 kV bus conductors are mounted and
secured against short circuit forces in molded, track resistant,
flame-retardant, non-hygroscopic support blocks of glassreinforced polyester. The UL molded support insulators are
ribbed to maximize both tracking distance and mechanical
strength. They are spaced as appropriate to maintain the
required short circuit strength of the bus. Semi-conducting
silicone rubber corona suppression inserts are used between the
conductor and support blocks. Porcelain is optional for 5 kV and
15 kV and is standard for 38 kV. The 600 V supports are
glass-reinforced polyester.
The bus conductors are completely enclosed in a grounded metal
housing for the protection of both personnel and property. The
housings may be totally enclosed depending on the type of instal­
lation, and may be fabricated from painted aluminum, steel or
stainless steel. Aluminum housings are standard and are
recommended for current ratings above 2000 A due to the effects
of hysteresis associated with ferrous, magnetic housing
materials, such as steel.
80
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
POWER-ZONE™ Metal-Enclosed Busway
nd
a
in.
)M
mm ax.
6
7
M
m– cm)
0c
. (3 t (732
n
i
f
3 24
ft –
B
C
1
A
C
Dual Dimensions: INCHES
Millimeters
Straight
Cross Section
OPG = B + 2.00
51
Horizontal Elbow
1.00
25
D
J
Upper Elbow
2.00
51
E
Duct centered in
wall opening
48.00
1219
Dual Dimensions: INCHES
Millimeters
OPG = A + 4.00
102
Phase Transposition
Lower Elbow
E
Dual Dimensions: INCHES
D
Millimeters
Vertical Elbows
Wall Entrance
C
Upper
I
E
H
G
E
F
Lower
Transition
Horizontal Tee
Vertical Tee
81
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
POWER-ZONE™ Metal-Enclosed Busway
Dimensions
Resistance
Watt Loss
Microhms
Per 3-Phase
Per Phase
Foot
Per Foot
Voltage
and
Material
Ampere
Rating
Wt/Ft
Lb
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
Copper
600
1200
1600
2000
2500
3200
4000
5000
6000
26
31
43
50
69
104
120
140
8.00
8.00
10.00
14.00
14.00
14.00
14.00
24.00
203
203
254
356
356
356
356
610
21.00
21.00
21.00
21.00
27.00
27.00
36.00
36.00
533
533
533
533
686
686
914
914
22.00
22.00
22.00
22.00
25.00
25.00
30.00
30.00
559
559
559
559
635
635
762
762
11.38
11.38
12.38
14.38
14.38
14.38
14.38
19.38
289
289
314
365
365
365
365
492
15.00
15.00
16.00
18.00
18.00
18.00
18.00
23.00
381
381
406
457
457
457
457
584
10.72
8.47
5.77
4.70
3.90
2.90
2.55
2.28
Aluminum
600
1200
1600
2000
2500
3200
19
23
29
33
43
8.00
10.00
14.00
14.00
14.00
203
254
356
356
356
21.00
21.00
21.00
27.00
27.00
533
533
533
686
686
22.00
22.00
22.00
25.00
25.00
559
559
559
635
635
11.38
12.38
14.38
14.38
14.38
289
314
365
365
365
15.00
16.00
18.00
18.00
18.00
381
406
457
457
457
Copper
5000 and
15000
1200
1600
2000
2500
3000
4000
5000
6000
29
35
50
59
77
112
126
150
14.00
14.00
14.00
14.00
14.00
14.00
24.00
24.00
356
356
356
356
356
356
610
610
27.00
27.00
30.00
36.00
36.00
36.00
42.00
42.00
686
686
762
914
914
914
1067
1067
25.00
25.00
27.00
30.00
30.00
30.00
33.00
33.00
635
635
686
762
762
762
838
838
14.38
14.38
14.38
14.38
14.38
14.38
19.38
19.38
365
365
365
365
365
365
492
492
18.00
18.00
18.00
18.00
18.00
18.00
23.00
23.00
Aluminum
5000 and
15000
1200
1800
2000
2500
3000
27
30
37
40
52
14.00
14.00
14.00
14.00
14.00
356
356
356
356
356
27.00
30.00
36.00
30.00
36.00
686
762
914
762
914
25.00
27.00
30.00
27.00
30.00
635
686
762
686
762
14.38
14.38
14.38
14.38
14.38
365
365
365
365
365
Copper
38000
600
1200
1800
2000
2500
3000
30
30
32
35
52
61
24.00
24.00
24.00
24.00
24.00
24.00
610
610
610
610
610
610
51.00
51.00
51.00
51.00
51.00
51.00
1295
1295
1295
1295
1295
1295
37.00
37.00
37.00
37.00
37.00
37.00
940
940
940
940
940
940
24.00
24.00
24.00
24.00
24.00
24.00
Aluminum
38000
600
1200
1800
2000
27
29
30
32
24.00
24.00
24.00
24.00
610
610
610
610
51.00
51.00
51.00
51.00
1295
1295
1295
1295
37.00
37.00
37.00
37.00
940
940
940
940
24.00
24.00
24.00
24.00
Voltage
and
Material
Ampere
Rating
Wt/Ft
Lb
IN
mm
IN
mm
IN
mm
IN
mm
IN
mm
Copper
600
1200
1600
2000
2500
3200
4000
5000
6000
26
31
43
50
69
104
120
140
48.00
48.00
48.00
48.00
60.00
60.00
60.00
60.00
1219
1219
1219
1219
1524
1524
1524
1524
22.00
22.00
22.00
22.00
25.00
25.00
30.00
30.00
559
559
559
559
635
635
762
762
18.25
18.25
19.25
21.25
24.25
24.25
28.75
33.75
464
464
489
540
616
616
730
857
28.00
28.00
30.00
34.00
34.00
34.00
34.00
44.00
711
711
762
864
864
864
864
1118
17.00
17.00
17.00
17.00
20.00
20.00
25.00
25.00
432
432
432
432
508
508
635
635
10.72
8.47
5.77
4.70
3.90
2.90
2.55
2.28
Aluminum
600
1200
1600
2000
2500
3200
19
23
29
33
43
48.00
48.00
48.00
60.00
60.00
1219
1219
1219
1524
1524
22.00
22.00
22.00
25.00
25.00
559
559
559
635
635
18.25
19.25
21.25
24.25
24.25
464
489
540
616
616
28.00
30.00
34.00
34.00
34.00
711
762
864
864
864
17.00
17.00
17.00
20.00
20.00
432
432
432
508
508
Copper
5000 and
15000
1200
1600
2000
2500
3000
4000
5000
6000
29
35
50
59
77
112
126
150
60.00
60.00
60.00
60.00
60.00
60.00
60.00
60.00
1524
1524
1524
1524
1524
1524
1524
1524
25.00
25.00
27.00
30.00
30.00
30.00
33.00
33.00
559
559
686
762
762
762
838
838
24.25
24.25
25.75
28.75
28.75
28.75
36.75
36.75
616
616
654
730
730
730
933
933
34.00
34.00
34.00
34.00
34.00
34.00
44.00
44.00
864
864
864
864
864
864
1118
1118
20.00
20.00
22.00
25.00
25.00
25.00
28.00
28.00
Aluminum
5000 and
15000
1200
1800
2000
2500
3000
27
30
37
40
52
60.00
60.00
60.00
60.00
60.00
1524
1524
1524
1524
1524
25.00
27.00
30.00
27.00
30.00
559
686
762
686
762
24.25
25.75
28.75
25.75
28.75
616
654
730
654
730
34.00
34.00
34.00
34.00
34.00
864
864
864
864
864
Copper
38000
600
1200
1800
2000
2500
3000
30
30
32
35
52
61
84.00
84.00
84.00
84.00
84.00
84.00
2134
2134
2134
2134
2134
2134
37.00
37.00
37.00
37.00
37.00
37.00
940
940
940
940
940
940
45.88
45.88
45.88
45.88
45.88
45.88
1165
1165
1165
1165
1165
1165
48.00
48.00
48.00
48.00
48.00
48.00
Aluminum
38000
600
1200
1800
2000
27
29
30
32
84.00
84.00
84.00
84.00
2134
2134
2134
2134
37.00
37.00
37.00
37.00
940
940
940
940
45.88
45.88
45.88
45.88
1165
1165
1165
1165
48.00
48.00
48.00
48.00
A
B
C
Reactance
Microhms
Per Foot
Impedance
Microhms
Per Foot
46
65
69
88
120
139
191
247
44.29
40.46
37.05
29.23
31.84
31.11
44.22
30.74
45.57
44.27
37.50
29.60
32.08
31.25
44.29
...
13.41
8.76
6.16
5.61
4.10
58
67
74
105
126
43.46
37.05
28.79
31.84
31.11
45.48
38.07
29.44
32.33
31.38
457
457
457
457
457
457
584
584
15.02
8.47
5.77
4.70
4.01
3.45
2.77
2.40
65
65
69
88
108
166
208
259
56.50
54.37
51.20
48.76
42.88
41.93
42.54
30.11
58.46
55.03
51.53
48.98
43.07
42.07
42.63
...
18.00
18.00
18.00
18.00
18.00
457
457
457
457
457
13.41
8.76
6.16
5.68
4.32
58
67
74
107
117
54.37
51.20
48.32
42.52
41.93
56.00
51.95
48.71
42.89
42.15
610
610
610
610
610
610
23.00
23.00
23.00
23.00
23.00
23.00
584
584
584
584
584
584
15.37
15.37
10.72
8.33
4.66
3.97
17
66
82
100
87
107
76.97
76.97
68.89
62.93
53.83
53.39
78.49
78.49
69.72
63.48
54.03
53.54
610
610
610
610
23.00
23.00
23.00
23.00
584
584
584
584
25.46
17.23
13.41
11.33
27
74
58
136
76.97
68.89
68.06
62.28
81.07
71.01
69.36
63.30
Reactance
Microhms
Per Foot
Impedance
Microhms
Per Foot
46
65
69
88
120
139
191
247
44.29
43.46
37.05
29.23
31.84
31.11
44.22
30.74
45.57
44.27
37.50
29.60
32.08
31.25
44.29
44.29
13.41
8.78
6.16
5.61
4.10
58
67
74
105
126
43.46
37.05
28.79
31.84
31.11
45.48
38.07
29.44
32.33
31.38
508
508
589
635
635
635
711
711
15.02
8.47
5.77
4.70
4.01
3.45
2.77
2.40
85
65
89
88
108
166
208
259
56.50
54.37
51.20
48.76
42.88
41.93
42.54
30.11
58.46
55.03
51.53
48.98
43.07
42.07
42.63
...
20.00
22.00
25.00
22.00
25.00
508
589
635
589
635
13.41
8.76
6.16
5.68
4.32
58
67
74
107
117
54.37
51.20
48.32
42.52
41.93
56.00
51.95
48.71
42.89
42.15
1219
1219
1219
1219
1219
1219
33.00
33.00
33.00
33.00
33.00
33.00
838
838
838
838
838
838
16.37
15.37
10.72
8.33
4.66
3.97
17
66
82
100
87
107
76.97
76.97
68.89
62.93
53.83
53.39
78.49
78.49
69.72
63.48
54.03
53.54
1219
1219
1219
1219
33.00
33.00
33.00
33.00
838
838
838
838
25.46
17.23
13.41
11.33
27
74
58
136
76.97
68.89
68.06
62.28
81.07
71.01
69.36
63.30
D
E
Dimensionsq
F
G
H
I
J
Resistance
Watt Loss
Microhms
Per 3-Phase
Per Phase
Foot
Per Foot
82
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
POWER-ZONE™ Metal-Enclosed Busway
Notes
Bus Bar Supports
• Performance values are calculated using a maximum
conductor temperature rise of 65 °C (149 °F) and the full
rated continuous current in a 20 °C (68 °F) ambient.
5 kV, 15 kV Glass-reinforced polyester standard; Porcelain
optional. 38 kV Porcelain standard.
• All data is based upon standard 3-phase totally enclosed
non-ventilated aluminum enclosures.
Housing Material
The table information is based on standard POWER-ZONE
bus construction. Other bus bar sizes and arrangements are
available to meet the purchaser’s required electrical
characteristics and space considerations. Use of steel housing
could require a derating of the busway. Consult the factory for
more information.
Bus Supports
POWER-ZONE Bus Standard Construction:
Aluminum standard; Steel optional.
Indoor trapeze hangers, outdoor single- or double-column
supports, and wall-mounted knee braces are available. Outdoor
structural steel supports are hot-dipped galvanized after
fabrication or primed and painted after fabrication as required.
Indoor supports are primed and painted to match the bus
housing color.
POWER ZONE™ bus is designed and constructed for unbraced
spans of 12– 20 ft (366–610 cm). Consult the factory for longer
unbraced spans. Recommended support heights, spacing, and
locations are determined by the factory and shown on the bus
drawings. Information on moments, reactions, and foundation
loading due to rain, wind, snow, or seismic forces can be
furnished upon request.
Bus Bar Material
Copper and aluminum.
Bus Bar Plating
• Copper-Silver (Contact).
• Aluminum-Tin (Contact).
The bus assemblies are mounted to their respective supports by
means of hold-down clip angles that permit longitudinal
movement of the bus duct to eliminate stresses from thermal
expansion and contraction.
Insulation
• 600 V Uninsulated; Fluidized bed epoxy optional
• 5 kV, 15 kV, 38 kV Fluidized bed epoxy
Type B
Double column support
(24 ft (732 cm) max. height)
Type C
Heavy duty wall support
(horizontal)
Type A
Single column support
(12 ft (366 cm) max. height)
Type D
Note: Drop
rods, anchors,
bolts, and
column support
foundations
are supplied
by others.
Trapeze hanger support
83
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
POWER-ZONE™ Metal-Enclosed Busway
Layout and Pricing Instructions
Wall Entrance Seal
A wall entrance seal consists of an external wall frame and a
vapor barrier which prevents air or vapor from passing from one
room to another or from outdoors to indoors. One-, two-, and
three-hour fire ratings are optional.
Fitting Description
• Non-segregated phase bus
• 600 V through 15 kV (1200 A–5000 A)
• Aluminum, steel, or stainless steel housing
Equipment Entrance Seal
• Aluminum or copper bus bars
• Insulated with fluidized bed epoxy (5 kV–38 kV)
• Complete line of fittings provides for any configuration
An equipment entrance seal should be used whenever a barrier
is required to prevent the passing of flame and or gasses
between the bus housing and the terminating equipment.
• Indoor trapeze and outdoor column supports
• For use in utilities, industrial, and commercial facilities
Expansion Fittings
POWER-ZONE bus is custom designed, manufactured and
tested per ANSI Standard C37.23 to meet customer
specifications. It is a completely coordinated package of
equipment with all the auxiliary material and supports for
connecting transformers, switchgear, MCCs, and motors, in all
types of utility, industrial, and commercial facilities.
An expansion fitting is used to counteract the strain placed on the
bus due to the expansion and contraction of the building or the
bus itself. One should be used whenever the bus run crosses a
building expansion joint and whenever a straight run of bus
exceeds 80 feet (2438 cm).
Housing Bellows (Misalignment) Collar
Transformer Connection
This type of termination should be used whenever the bus is
connecting to a transformer, motor, switch, or any connection
where the bus bars are connecting to porcelain-mounted
equipment terminals. It will include the same components as a
flanged end plus one set of flexible braid-type connectors and a
terminal box (if required.)
Generator Connection
All "Transformer Connection" information applies with the addition
that an enclosure bellows should be included when the busway
attaches to a generator.
Required at terminations or wall penetrations when equipment
vibrations or seismic forces may cause damage to the bus. It may
also be used to adjust for the "settling" of terminating equipment
after installation.
Flanged Ends
A flanged end is used to terminate the bus into switchgear, motor
control centers, switchboards, or any rigid bus-to-bus connection.
It consists of a gasketed equipment flange, up to
1 foot (30 cm) of 3Ø-3W conductor (3Ø4W as applicable),
necessary insulation tapes, and required bolting hardware. If
additional conductor length is required, add to the footage price
on a per foot basis.
Bushing Box (Weatherhead)
A bushing box is used on service entrance run where the cable
connection to the bus must be made via porcelain bushings. It is
comprised of the same components as a transformer connection
plus three-through stud-type apparatus bushings, bushing stud
connectors (lug pads), and a strip heater.
Cable Tap Box
A cable tap box includes a gasketed and accessible termination
box, lugs, necessary insulation tape (between bus and lugs only),
and required bolting hardware. Lug sizes and quantity should be
specified by purchaser.
Ground Bus
Supporting Steel (Hangers)
The bus housing is designed and constructed to provide an
electrically continuous ground path. The side rails of the bus
housings are capable of carrying the full-rated phase current
continuously and, under short circuit conditions, are capable of
carrying fault current for three (3) seconds. Consequently, a
separate ground bus is not necessary unless specified.
Supports are not included in the "per foot" price of the bus and
should be added on the basis of one for every 12 to 15 feet
(366 to 457 cm). Indoor supports are a trapeze type hanger while
outdoor supports are a single- or double-column type support.
Consult the factory for other type supports.
Hazardous or Seismic Locations
Consult the factory for bus runs that are to be installed in a
location that is classified as hazardous or in a Zone 3 or 4 seismic
location.
84
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
POWER-ZONE™ Metal-Enclosed Busway
General Pricing Instruction
1. Prepare a layout sketch (if applicable) of the run(s) showing
all dimensions in feet and inches, all wall and floor locations
and thicknesses and all fittings such as elbows, tees,
flanged ends, cable tap boxes, expansion fittings,
transformer connections, etc.
2. Add all dimensions together using the center line of the bus
and adjust the total to the higher whole foot.
3. Multiply this total by the per foot price as determined by the
type (indoor or weatherproof) (aluminum or copper) and the
number of poles and any optional accessories (aluminum
or steel enclosures, fiberglass or porcelain conductor
supports, etc.,). To this, add the charges for each of the
elbows, tees, flanged ends, cable tap boxes, expansion
fittings, transformer connections, etc.
4. The sum of these items plus the sum of any optional
accessory is the price of the entire bus run.
Note: Because the bus run is custom-designed and built, there
are no “Complete Device” prices.
Bus Footage
The per foot price of the bus may be a combination of several
prices depending on the job specifications and requirements.
Some of these options are special momentary rating, special
housing material and/or finish, special conductor supports,
heaters and thermostats, and ground bus.
Weatherproof Bus
Weatherproof bus is priced the same as indoor. In addition, all
weatherproof runs must be equipped with strip heaters to
eliminate condensation and, if applicable, a thermostat. A heater
should be priced for every seven feet (213 cm) of bus and no
more than 20 heaters can be controlled by one thermostat. Also,
each bus run should have its own thermostat. The heaters
operate at 120 V.
5. Contact your local representative for assistance in laying
out or pricing this product.
Typical Layout
Indoor
90 Horizontal Elbow
Vertical
Tee Tap
Outdoor
Wall
Entrance
Assembly
Cover Joiner
Strip
Splice Covers
Phase
Transposition
Heater
Thermostat
Heater
Termination
Box
Flanged End
Wall Support
Cover Joiner
Strip
Switchgear
Cubicle
Flanged End
90 Vertical Elbow
Hanger Support
Horizontal
Tee Tap
Termination Box
Flanged End
Removable
Heater Assembly
Flexible
Connectors
Column Support
Switchgear
Entrance
Bushing
85
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Busway Systems
POWER-ZONE™ Metal-Enclosed Busway Suggested Specifications
1.0 General
1.1 Section Includes
a. This specification describes the electrical and mechanical
requirements for metal-enclosed, 600 V through 38 kV
class, 60 Hz feeder bus. The bus system described is to be
suitable for indoor and outdoor installations, with nominal
current ratings maintained in ambient temperatures to 40°C
(104 °F).
b. This specification covers only the general requirements of
the bus duct assemblies. The specific requirements of each
assembly (plan, arrangement, components, etc.) will be
shown on drawings provided by the Purchaser. These
drawings form the basis for manufacturing and installation
drawings developed by the Vendor.
d. Space heaters shall be completely factory wired except
shipping split connection. Heaters shall be [thermostatically
controlled] [manually controlled]. Heater wiring shall be
[terminated in a junction box at designated end of bus
housing] [provided with 3-ft (91 cm) coiled extension for
connection into Purchaser’s switchgear power source].
Heaters shall be rated at 240 V and operated at 120 V
(1/2 voltage) to maintain low heater surface temperature.
e. All housing and flange gasketing shall be EPDM or other
noncorrosive material, and shall be completely concealed
for protection against deterioration.
f. The temperature rise at any point on the housing shall not
exceed 30 °C (86 °F) above an ambient temperature of
40 °C (104 °F).
g. A fire resistant divider or barrier shall be provided at all
points where the bus duct extends through building walls.
1.2 References
2.3 Phase Bus Bars
The assemblies shall be constructed, wired and tested in
accordance with all applicable sections of the latest listed
standards and codes.
• NEMA–National Electrical Manufacturer Association
• ANSI C37.23–American National Standards Institute
• NFPA 70–National Electrical Code
a. Phase bus bars shall be of the metal-enclosed busway
type.
b. Bus bars shall be full round edge rectangular [98% IACS
copper] [57% IACS aluminum] of sufficient cross-section to
provide full current rating without exceeding a hot spot
temperature rise of 65 °C (149 °F) in a 40 °C (104 °F)
ambient.
c. Phase bus bars shall be mounted and secured against
movement during short-circuit in tracking-resistant, glassreinforced polyester blocks, or an approved equal, spaced
along the bus run as required to meet the short-circuit
current rating. The support blocks can be ribbed to provide
long creepage paths and fitted with corona suppressors,
consisting of silicone rubber inserts between the insulated
bus bars and support blocks.
2.0 Products
2.1 Manufacturers
Square D Company–Metal-Enclosed Busway
2.1 Housing
a. The bus duct shall be nonlouvered outdoors and indoors.
Housing and accessory flanges, terminal enclosures, etc.,
shall be primed and painted [steel] [corrosion resistant
aluminum] construction. All outdoor hardware exposed to
the weather shall be stainless steel. Indoor hardware
(unless in corrosive environment) shall be manufacturer’s
standard.
b. Bus housing shall be steel or aluminum.
c. Outdoor, totally enclosed, nonlouvered housings shall be
fitted with screened breathers and space heaters in
sufficient quantity and rating to minimize condensation.
d. Phase bus bars, at 5 kV class and above, shall be insulated
with epoxy, rated for continuous operation at 130 °C
(266 °F).
e. Contact surfaces of copper bus bars shall be silver plated
electrically by tank or brush method. Contact surfaces of
aluminum bus bars shall be electro-tinned. All bus bar
connections shall be bolted.
f. Bolts shall pass through the bus bar conductors, and shall
be capable of being properly torqued and locked in place,
to provide and maintain full and uniform pressure under all
operating conditions. (Torque requirements in ft/lb shall be
furnished by Manufacturer.)
86
© 1997–2002 Schneider Electric All Rights Reserved
08/02
Busway Systems
POWER-ZONE™ Metal-Enclosed Busway Suggested Specifications
g. In no case shall the temperature of such bus bar joint
exceed 65 °C (149 °F) above an ambient temperature of
40 °C (104 °F). An internal ground bus [shall] [shall not] be
furnished which will electrically connect together all
equipment connected to the bus duct.
h. If the bus duct enclosure is so constructed and connected
that it provides a continuous path for ground current, it may
serve as the ground bus. If the enclosure is used as the
ground bus, a tooth-type lock washer shall be furnished
under each bolt head and each nut at connections between
sections of bus duct. If the enclosure is not so constructed,
the bus duct shall be furnished with a [aluminum] [copper]
ground bar inside the housing. The ground bus shall have
suitable terminating pads for Purchaser’s connections to
station ground system.
i. Flexible connectors shall be provided for connecting bus to
porcelain apparatus bushings. All necessary adapter bars
and spacers, bolting hardware and insulating materials, for
connections to transformer or switchgear terminals, shall
be provided and the proper coordination of connections
between bus and terminal equipment shall be the
responsibility of the bus Manufacturer
j. Purchaser will provide Manufacturer with applicable
switchgear and transformer drawings for matching and
coordination requirements prior to fabrication.
2.4 Ratings
a. The maximum hot-spot temperature rise at any point in the
bus, at continuous rated load, shall not exceed 65 °C
(149 °F) above an ambient temperature of 40 °C (104 °F).
b. The ratings of the bus duct shall be:
— Voltage Class: ___ Volts
— Continuous Current Ratings: ___ Amperes
— Short Circuit Rating: Momentary Current Amps
___ RMS asymmetrical.
— Short Time Current Amps ___ RMS symmetrical. (Not less than short time ratings of protective devices.)
— Basic Insulation Level (BIL): ___ kV
2.5 Supports
Bus duct supports shall be [indoor trapeze type] [outdoor
column type with base plates for attaching to Purchaser’s
foundations] [knee-brace type for wall mounting].
87
08/02
© 1997–2002 Schneider Electric All Rights Reserved
Square D Company
5735 College Corner Rd.
Oxford, OH 45056, USA
1-888-SquareD
(1-888-778-2733)
www.SquareD.com
Schneider Canada Inc.
19 Waterman Avenue,
M4B 1 Y2
Toronto, Ontario
1-800-565-6699
Catalog No. 5600CT9101R8/02 August 2002 © 1997–2002 Schneider Electric All Rights Reserved
www.schneider-electric.ca Replaces 5600CT9101R4/01 dated 09/01.